MAXIMUM Fabrication and Installation Manual

INSTALLATION
FABRICATION
Contents
Introduction
Size and weight
Fact sheets – suitability for applications
Handling and storage
3
3
4,5,6
Fabrication instructions
2
Toolsandequipment
BasicfabricationmethodforcuttingPorcelainPanelsonwetsaw
Cutoutsforunder-mountedorsurface-mountedsinks
Joinery, Installation & Fabrication Tips
Safety guidelines & Care and maintenance
Basic fabrication method for cutting Porcelain Panels cuts outs,
holes by hand powered tools
7
7,8,9
10
11,12
Contact
15
13,14
Introduction
Madefrom100%allnaturalminerals,theyaresustainablefortheharmfulelementsthathave
beenleftout:theycontainnosealants,waxes,epoxies,man madebindersorartificial colouring
agentsthatcouldaddtoharmfulVOCemissionafterinstallation.
Size and weight
Maximum Porcelain Panel size specification:
Panel size: 3000 x 1500 x 6mm
Weight:
14.67kg/m
Total area:
4.5m
2
2
Maximumcomesinavarietyoffinishes and sizes may vary pending on the finish.
Please refer to web site.
Applications
Maximumapplicationsinclude:allexternalwallcladding,internalfloor and walllinings,shower
recesses,kitchenbenchtop/splashbacks,vanities,andapplicationsoverexistingfloors orwalls.
• Suitableforalldomestic,commercial,retail,multi-residentialandrefurbishmentprojects
• Maximumismadefrom100%naturalmaterialwithup to 40%recycledcontent
• Nochemicalbindersorresinsareused
• MaximumisUVresistantandcanbeusedexternally
• Highstrengthandscratchresistance
• Thermalshockresistance
• Stainandmouldresistance
3
Handling and storage
Seevideolink:http://www.youtube.com/watch?v=RNn_B75EUk0
Description
1
MaximumPorcelainPanelscan bepackedflat intimbercrates–dimensionsare3200x1640mm
or delivered on A-frames. Approximateweightforcratecontaining12slabsis980kgs.Forklift
extendersmustbeusedwhenmovingcrates.
2
Forthecorrecthandlingofthecrates,aforkliftmustbeusedwithatleast1.8mlongforklift
extendersforsideonlypositioningtocrate,withtheforkspositionedinthemaximumwidthposition
(seeFigure1).Undernormalconditions,theforksarepositionedinthemiddleofthelongsideof
thepallet,astheymustgripthewholedepthofthepallet(seeFigure2).
If2.5mforkliftextendersandcorrectforkliftareavailablethecratescanbemovedasshownin
3
illustration(SeeFigure2).
H-1640mm
Min.
H-1200mm
Min.
Whenremovingcratesfromcontainers,itisrecommendedtomoveonly1crateatatime.Removal
eitherbycraneliftingwithslingsoutoftoploadcontainersorbyusingcorrectfork
liftblades.Toallowtheextractionofthepanelseasilyandsafely,itisrecommendedtopositionthe
cratesinasuitableareawheretheforkliftcanbemovedaroundallsidesofthecrate.
700mm
Min.
800mm
Min.
Stacking Crates
Cratesaredesignedtostacktoamaximumof6cratesinheight.
Crate Capacity
Cratesaredesignedtocontainamaximumof12panels
H-2500mm
Min.
800mm
Min.
4
H-2400mm
Min.
700mm
Min.
Handling & Storage - Continued
From Crates - formanualhandlingandsubsequentlayingoftheMaximumpanels,inorderto
guaranteetheoperator'ssafetyandtheintegrityofthepanels,itisstronglyrecommendedtousea
framewithsuctioncups.ThefullframeisparticularlysuitableforlargedimensionMaximumformats
(e.g.3000x1500mm–1500x1500mm)whereasonsmallerMaximumformats(e.g.1500x750mm)
twodoublesuctioncupsaresufficient.
1
Preparation stages:
1. Positiontheframewithsuctioncupsonthepanelandmakesurethatthecupsadheretoitperfectly
(seefigure3).
2. Forhorizontalhandling(onthesurface),putthepanelintoaverticalpositionandusethewheels
appliedtothehandlingframe.
Instruments required
Theinstrumentsforliftingandhandlingthepanelscanbechosenaccordingtothesizeofthe
panelandtheactivitiestobeperformedonthesite.(see accessories-page14).
Note:Suctioncupsonlyworkeffectivelyonthefaceofpanelsandnottherear.
3
5
2
Handling & Storage using A-Frames - Continued
On A-Frames – ensure that for deliveries an oversized stone slab or board is supplied on the
steel A-frame as backing support. Strap in Maximum to ensure no horizonal movement occurs
during transport.
Solid rubber matt – 12.5mm
available from Bunnings
Moving slabs with vertical clamp and overhead crane. To assist moving individual 6mm panels
where the clamp doesn't close to 6mm or 18mm a rubber saddle can be made up see photos or vacuum suction lifters can be used.
Handling benches or splash backs
Transporting to site – in particular benches with cut outs. Lay bench against a solid
substrate such as MDF or similar, ensure that backing support is at least 2cm wider than the
benchtop, strap or tape both together, so handling will be easier and will avoid potential
damage to panels in particular to cut outs.
Always carry panels edge on ie: vertically not horizontally.
6
Tools and Equipment for Stone Fabrication
In achieving quality workmanship it is essential that the correct equipment and cutting methods are used.
Basic equipment
NormalprocessingequipmentthatisusedformarbleandgraniteissuitableforMaximumPorcelain
Panels.Bladesandmillingtoolsmustbesuitableforwetcuttingporcelain.
Note: Unlike other engineered stones de stressing panels by trimming edges is not required with Maximum.
Basic fabrication method-Tipsforcuttingporcelainpanelsusingabridgesaw or water jet.
Note: these tips are only recommended guides and that different methods can be explored.
• Mustuseasolidbase,suchasaflat stoneslab–slightlylargerthan3000x1500mm
Maximum panel showing cut out for kitchen sink.
• Continuouswaterflow
• Onlyrunslowcuts.Stepcuttingisanoption, as well as first creating a small step cut at opposite end
• Useasuperiorqualitycontinuousporcelainblade
• Usehandlingequipmentasrequired
• Onmitrecuts–itisrecommendedtoavoidsharpedgemitres
• Itisrecommendedtoweighdownpanel,toavoidanyflexorvibrationinproductwhencutting
• Itisrecommendedwhencuttingsmallerpanelstousestoneoffcutsaroundperimeteredgeofpaneltominimisepanelmovement
• It is importanttocontinually keep blade sharp by using a sandstone block or pumice and re sharpen every 4-5 cuts.
7
Bridge Saw
CNC or Water Jet machines
Mitre Saw
Use continuous diamond
porcelain cutting wheel.
Use milling bits suitable for porcelain work on
CNC or water jet machines.
The central component to cut accurate mitres for a wide range of applications on
engineered stone, granite and marble of thicknesses.
Accuracy is the key when cutting
mitres.
The more accurate the cut, the better the result. Tools and Equipment for Stone Fabrication - Cont’d
Create a solid oversized and flat stone base to work on, such as granite or a quartz composite.
Set up a straight edge along one side to ensure straight cuts.
8
For smaller pieces - set up a straight edge along one side using a stone section to ensure no movement occurs.
Tools and Equipment for Stone Fabrication - Cont’d
Maximum Moon–Countertopwith19mmFC(FibreCement)substrategluedwithMegabond
adhesive.For optimum results on a mitreedge use Akemi Akepox5010.
9
Lightweight substrates can be used, such as PVC rigid
foam board to assist in fabrication & handling. The board
is fully adhered to Maximum Panels. This also assists in
producing mitred aprons. Note: This substrate does not
replace rigid on-site joinery substrates.
Cleaningtip–useGlitzGreen
Eucalyptusoiltoremovedust,
cleanandrevitalisesurface
finishafterinstallation or
Porcelain Creme from Spirit
Marble & Tiles.
Cut outs for under-mounted or surface mounted sinks.
Square cuts -Useadiamondcoredrillateachcorner,thencutwithsaw.
Curved corners -Forundermountedbasins-curvedcutscanbeconsideredin
conjunctionwithequipmentlimitations.
Under mounted -Useadiamondcoredrill,diametertosuitradiusofcurveand
thencompletecutonCNCorBridgeSaw.Honeasrequiredwithsmallarisaround
topedges.Water Jet would not require these steps.
Werecommendthatalldrilledholesorcutoutsbelocatedthroughapplicationand
markingofsuitabletape.Itisalwaysbesttouseatemplateforanydrilledholeto
ensurecorrectlocationisachieved.
Joint treatment - Werecommendalljointsbetapedpriortoapplicationofany
jointslantsuchassiliconorcolourmatchedresin.Nojointsealantshouldbe
allowedtotouchthefinishedsurfaceofthepanel. Do not work on the face of the
panel with pads or buffers
Edge treatments - WithMaximumPorcelainPanels,variousmethodscanbe
usedwithexcellentsuccess.Manykitchenbenchtopsarenowbeing
manufacturedwithaslimnaturalprofileusingastraightedgethatdoesnotrequire
polishing.Althoughedgescaneasilybepolishedifrequired.
Exposededgesarebestfinishedtominimisepotentialforchipping.
Someexamplesincludearis,halfbullnose,bullnose,pencilroundetc.
Mitred edges - Amitrededgecanbeachieved(asperpicturemiddleright). Itis
recommendedthatthejunctionbetweenthemitrebesuitablyworkedsoasto
minimisesharpedges,generallya1mmarisorlightpencilroundiseffective.
Whensettingupmitremachine,avoidsharpedgemitres.
Calacattamitrededgewithapron
Otheredgesthatcanbeachievedincludebuttjoint,birdsmouthetc.
Apron returns - Canbeproduced.(seeCalacattamitrededgewithapron
photo).Inthisexamplecasestudya40mmapronwithmitredjointwasfabricated
usinga9mmFCsubstratetoadhereMaximumto,19mmmarineplypackers/
spacers,thenmarineplyspacersusedforfinalbeddingovercabinetbattens.Itis
uptothefabricatortoworkoutbestsolutionspendingonskillset.CFC,MR MDF,
FC,MarinePly,mediumgradeplyareallproductsthatmaybesuitableforthe
substrate.
Straightedgefinis with2mmaris
Adhesives for substrates and mitres - Most fabricators will have a knowledge of best adhesives to use. We recommend, Mapei Keralastic T Polyurethane
or Mapei G19 for adhesion to substrates.
Always respect manufacturers curing times for adhesives before completing further works such as coring holes or working above the finished Maximum installation.
For mitre joints - Akemi Akepox 5010 epoxy adhesive has excellent adhesion for porcelain.
Repairs - For chips and other, we recommend Akepox 5010. Akemi colouring paste is available or the Akelux stone repair system.
10
Joinery & Fabrication Tips.
6mm Maximum Porcelain Bench Top
Substrates for Countertops
Alwaysusearigid and continuous moisture resistant substratesuchasMR MDF, CFC,FCor other and ensure
that the substrate has no flex.DonotinstallMaximumpanelsovertimbersupportbenchbattenswithoutasuitable
substrate.
6
1
2.5
Adhering Maximum to substrates & splash backs
When glueing panels to an existing substrate or splash back you must ensure that the adhesive spread has 100%
coverage of at least 2-3mm thick. Do not leave airgaps under bench tops. Ensure that manufacturers curing
times are adhered to before any works are performed such as core drilling, plumbing or on-site cut outs.
2-4mm
Adhesive
100% Coverage
Rigid substrate
moisture resistant
MDF or other
Kitchen Sink
Overhangs
Recommendflushfinishtobenchesormaximum20mmoverhang with angle support - see drawings. Iflarger
overhangsarerequired for Island Benches,useasuitable supportsubstratetominimiseanypotentialdamageto
materialduetoheavyimpact or flex. Again substrate must be rigid such as a moisture resistant 32mm MDF.
Rebate
substrate
detail
Joinery
Undermounted sink and fixing taps - see fig. 01
To avoid hairline cracks, do not adhere sinks to underside of porcelain only. Ensure that sink lip is rebated to
substrate. Most importantly avoid over tightening tap fittings - ensure that Maximum sits flush to edge of
substrate and that porcelain and substrate both support tap base and fixing. Best solution for fitting taps is to fix
the tap base housing direct to substrate, which means enlarging the hole on Maximum so that the tap base
can be recessed (ensure that silicon is used to prevent moisture ingress). Only use silicon to adhere sink lip
(aluminum or stainless element) to Maximum (due to thermal movement of metal) and adhesive to fix Maximum to
substrate. Ensure that the silicon and adhesive sit at the same level and thickness.
01 REBATED UNDER MOUNTED SINK DETAIL
Top Mounted sink
Ensure that maximum sits flush to edge of substrate and that porcelain and substrate both support sink weight.
1
Edge distance to cut out.
We recommend a minimum 80mm to any edge, pending cook-top or sink sizes and hole for the tap, and cut out a
minimum of 50mm to any edge of hole from back wall and edge of sink.
1
Cut Outs for sinks or cook tops
Cutouts, such as for sinks and cook tops, should have rounded internal corners (min 10mm radius) to prevent
radial cracking. Specifically items like shower niches, fireplaces etc where the porcelain might be expected to return
in from one or more faces with a mitred or butt joint. It is essential that the face panel is sectioned around this type
of opening to avoid stress points in the product, where subsequent movement in the structure may cause a fracture.
Quick Tips
Panel Inspection Prior to fabrication ensure that panels have no visible defects such as blemishes, surface
markings or damage.
Recommended Porcelain blades Contact Farnese: Piero 0488 065 846 [email protected]
Sharpening Blades Use a pumis or sandstone block and resharpen every 4-5 cuts.
11
Honing edges & Aris Sandpaper Grit - Matt finish: 120,220 G. Polished finish: 120,220,400 used with water
6mm Thick Maximum Bench Top
100% Adhesive fixed to moisture
resistant continuous rigid substrate
Metal Angle 50 x 20 x 1.6mm
To be fixed to support substrate
Adhere porcelain bench top to
substrate and angle, ensuring
adhesive cover to angle as well
02
TYPICAL KITCHEN BENCH EDGE DETAIL
Joinery & Fabrication Tips - continued
Recommended Adhesives for Substrates & Mitres.
Mapei Keralastic T adhesive or Mapei Adesilex G19 (available
from Masters) for substrates.
Akemi Akepox 5010 for Mitres - www.golz.com.au/proakemi.html
6
1
GAP
1
25mm Continuous Fingerpull
Drawer Front
03
KITCHEN BENCH FINGER PULL OPTION 1
2.5
6
2mm folded metal angle
MaximumPorcelainPanelsarestainresistant,butcaremustbetakento
immediatelycleanoffstains,especiallyonpolishedbenchtops.Bestwayto
ensurestubbornstainsdonotoccuristoimmediately washawaystainssuchas
redwine,food and drinks,usingwarmwaterandasoftcloth.
Forstubbornstainsuseanon abrasivecleaningproduct,sugarsoapornormal
housecleaningproducts.DonotusecleanersthathavestrongalkalinepHlevels
andthoroughlyrinsethesurfacewithcleanwatertoremoveresidue.
1
.5mm
Laminate to
Substrate
Door Pulls
Doors
Heat resistant
AlthoughMaximumisthermalshockresistant,itisalwaysadvisabletousea
placematorsimilarwhenplacinghotpotsonthebench.
04
KITCHEN BENCH FINGER PULL OPTION 2
Safety guidelines when fabricating
WearinganapprovedfacemaskwhenfabricatingMaximum.Alwayscutandfabricatewithwetdiamondtoolsandtakeappropriatemeasuresto
provideefficientventilationintheworkarea.Alwayswearapprovedeye,bootandhandprotectionwhenfabricatingporcelain.
12
6mm Thick Maximum Bench Top
100% Adhesive fixed to moisture
resistant continuous rigid substrate
Metal Angle 50 x 20 x 1.6mm
To be fixed to support substrate
Adhere angle to Porcelain Bench Top
GAP
Avoid blow outs when cutting with wet saw
Either cut a small step cut at opposite end and slow speed down
or begin and finish cut with slow speed. Always trial cuts from
offcuts. CNC tools must be sharpened prior and between
operations. Correct feed rates used as per CNC tooling
parameters.
Care and maintenance
Maximum Porcelain Panels - Options for supports on overhangs
Notes:
1. Ensure that the substrate is rigid.
2. 100% adhesive coverage is required when applying Maximum Panels to substrate
2.5
Cutting Speeds for Bridge Saw
As a guide only pending equipment type-1000mm per min and 500mm per min for mitres.1850
to 1900 RPM pending equipment.
Water Jet
Table slats in perfect condition, with as little distance as possible to give full support. Water level
at the height of the slats and 3mm between the nozzle and the slab. Abrasive used to cut
Maximum should be 300 gr/min. (recommended grain 80 micron.) Cutting pressure used for
Maximum: Firstly start drilling at 700bar and continue with high pressure cutting at 3500bar
(starting piercing for 10 seconds) (parameters depending on the machine).
6mm Thick Maximum Bench Top
100% Adhesive fixed to moisture
resistant continuous rigid substrate
Basic Fabrication Method - Forcuttingporcelainpanels,cutoutsandholesbyhand-poweredtools
http://www.youtube.com/watch?v=RNn_B75EUk0
MAXIMUMcanalso beeasilyprocessedbyusingsomesimplehandtools.Itisrecommendedtoprocesstheslabsonaflat
worksurface,atleast5cmlongerthantheslabfromeachsideordoublesuctioncup.Oneoperatorissufficientforcutting
theholes.
Cutting
Instrumentsrequired-dependingonthetypeofcutandprocesstobeappliedtothepanel,therecommendedtooltypesarelisted
below:
• Handling frame with suction cups or double suction cups
• Cutting guide with cutting carriage for linear cuts of 150/300 cm
1
2
3
4
• Cutting pliers
• Wetcorediamond drill bits
• Angle grinder with diamond blade
• Diamond buffer
Linear cuts and scoring
1. Marktheportiontoberemovedattheendsoftheslab(seeFigure1).
2. Positionthecuttingguidewithcuttingcarriagesothatthereferenceson
theguidecoincidewiththelinesmarkedonthepanel.Lockthecutting
guidewiththecuttingcarriageinplaceusingthesuctioncups.
3. Toguaranteecorrectscoring,thepressureandmovementofthe
cutting carriagemustbeconstantalongthewholelengthofthecut.
4. Scoreoneendofthepanelby15cmpushingthecuttingcarriagetowardstheedge
ofthepanel(seeFigure2).Completethescoringuptotheoppositeendofthepanel.
.
Completing cuts
1. With cutting guide move panel until scoring line protrudes 5/10cm from work surface.
2. Release the cutting guide from suction cups and move towards the middle of panel.
3. Start cutting off process by positioning cutting pliers in line with line scored on panel (see Figure 3).
4. Exert progressive pressure until you notice that cutting off process has begun.
5. Go to opposite side and position cutting pliers in line with line scored on the panel.
6. Exert progressive pressure until you notice the cutting off process has begun.
7. To complete the cutting off process, one or more operators must grip the portion to
be removed and exert progressive pressure downwards (see Figure 4).
8. Thefinishing oftheedgesonthecutsidemustbecarriedoutusingthespecialdiamondbuffer(seeFigure5).
13
5
Basic Fabrication Method - ForcuttingPorcelainPanels,cut outs,holesbyhand-poweredtools
L-shaped cuts
For L-shaped cuts (holes for electrical boxes, internal corners) it is
recommended to round off the internal angle by making a hole first with
suitablewetcorebits.
Square cuts/cut-out
Marktheportiontoberemovedonthepanel.
Tolimitthepossibilityofbreaking,itisrecommendedtomakea.7mmhole
in-linewiththepointwherethetwolinesmarkedonthepanelmeet.
Withananglegrinderequippedwithadiamondblade,followthemarked
lines. All square cuts at any size require a radius hole at every corner
before commencing cuts.
Rectangular holes
Markthesidesoftheportiontoberemovedonthepanel.
Makeradiusholesinthe4corners.
Usingananglegrinderequippedwithadiamondbladejointhe4holes.
1
Round holes
1. PositiontheMaximumpanelonasolid,non-slipsurface (e.g.woodor
concrete). To avoid drill bit slipping whilst drilling, a pre cut round
template could be used as a guide made from a 20mm stone.
2. Using a diamond core bit (hole cutter), spraywaterontotheareawhere
theholeistobemade.
Starttomakeaholeatanangleof75°-85°andpenetrateintothe panel
withadepthofabout1-2mm.
Keepthedrill/screwdriverata90°angleandmakecircularmovements
withanangleofabout5°-10°.
3. Donotexerttoomuchpressure.
Donotpushstraightdownwards.
Makesurethereisenoughwatertowetthecutter. Cleanupthescraps
oncetheholehasbeenmade.
14
2
3
To find the best Maximum solution for your project contact
P +61 2 9519 8017 W www.maximumaustralia.com
TH EUROPEA
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EN 12004
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ADHESIVE FOR C
Two-component,
high-performance,
polyurethane adhesives
for ceramic tiles and
stone material
CLASSIFICATION IN COMPLIANCE WITH
EN 12004
Keralastic is an improved (2) reaction resin adhesive (R)
as class R2.
Keralastic T is an improved (2) reaction resin adhesive
(R) and slip resistant (T) classified as R2T.
Conformity of Keralastic and Keralastic T is declared
in ITT certificates n° 25040320/Gi (TUM) and
n° 25040471/Gi (TUM) respectively, issued by the
Technische Universität München laboratory (Germany).
WHERE TO USE
Indoor and outdoor, bonding of wall and floor ceramic
tiles, stone material and mosaics of all types on:
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PVC, reinforced polyester, asbestos-cement, gypsum,
gypsum board, gypsum panels, etc.
Some application examples
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of mosaics in showers and on sheets used for
prefabricated bathrooms.
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work surfaces or in kitchens in order to achieve a
waterproof substrate.
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on balconies, external terraces domes or flat roofs
subject to foot traffic.
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(marble of every type, slate, etc.) also subject to
movement and size variation due to the absorption
of water (class C of size stability according to MAPEI
standards).
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subject to vibrations and deflections.
TECHNICAL CHARACTERISTICS
Keralastic and Keralastic T are two-component,
solvent and water free adhesives which are flexible and
waterproof. They are made up of a polyurethane base
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On mixing the two components together, the result is a
paste with the following properties:
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šKLJKGHIRUPDELOLW\
šLQWKHFDVHRIKeralastic T, highly thixotropic: it can
be applied vertically without slump and without letting
even heavy or large tiles slip. The slipping strength is
in compliance with EN 1308.
RECOMMENDATIONS
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a risk of rising damp.
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mixing ratio could cause damage during the curing
process.
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immersion in water, consult the MAPEI Technical
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š'RQRWXVHKeralastic and Keralastic T to bond
transparent glass materials.
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Laying on an old PVC
floor
Waterproofing
and laying in a
prefabricated shower
unit
APPLICATION PROCEDURE
Preparing the substrates
The substrates must be cured, mechanically
strong, free of loose particles, grease, oil,
paint, wax and be sufficiently dry.
Cement substrates must not be subject to
shrinkage after the installation of the tiles.
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be cured for at least one week for every
centimetre of thickness and cementitious
screeds must be cured for at least 28 days,
unless they have been made with MAPEI
special binders for screeds such as
Mapecem, Mapecem Pronto, Topcem
or Topcem Pronto. Where this is not
observed, the adhesion of Keralastic and
Keralastic T to the substrate will be greatly
compromised.
Rust on iron surfaces must be removed by
sandblasting. It is recommended to reinforce
gypsum, gypsum board and anhydrite
substrates with a coat of Primer EP or
Primer MF.
Preparing the mix
The two components of Keralastic and
Keralastic T are supplied in ready-to-mix cans:
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weight.
The ratio of the resin (component A) and the
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modification could cause incorrect hardening
of the product.
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component A and mix well until a uniform
grey or white paste is obtained. It is advisable
to use a low speed electric stirrer to ensure
perfect mixing and avoid overheating the mix,
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the mix within 30-40 minutes of mixing.
Applying the mix
Apply to the substrate a uniform layer of
Keralastic or Keralastic T with a notched
trowel. Choose a trowel that will give a
coverage to the back of the tiles of at least
65-70% (see “Consumption”).
For exterior installations, the tile backs must
be completely covered with the adhesive.
When both waterproofing and bonding are
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worktops, one of two procedures may be
followed:
šVSUHDGKeralastic on the substrate with a
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then rework the surface with a notched
trowel so as to line it all over, but without
reducing the thickness to less than 1 mm.
This thickness must be maintained even
after the tiles have been installed, especially
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šVSUHDGKeralastic with a flat trowel
to a uniform thickness of 1 mm for
waterproofing and, after hardening (in any
case within 24 hours), apply a second layer
of Keralastic with a notched trowel.
Installing the tiles
Tiles must be absolutely dry.
Apply firm pressure to the tiles to ensure
good contact and covering of the back. If
the layer of fresh Keralastic or Keralastic T
is also to act as a waterproofing membrane,
make sure that any ribs and lugs do not go
through the layer.
If Keralastic or Keralastic T is used for
installing onto particularly deformable
substrates, all coverings larger than 5x5 cm
must be installed with wide joints.
The open time of Keralastic and
Keralastic T under normal temperature
and moisture conditions is approximately
50 minutes. Any adjustment must be carried
out within 90 minutes of installation.
The setting time is strictly tied to the ambient
temperature (see table below).
Setting time of Keralastic and Keralastic T
in relation to the temperature:
7HPSHUDWXUHƓ&
Time (hours)
30
25
20
15
10
2
3
6
8
20
GROUTING AND SEALING
Joints between the tiles can be grouted
after 12 hours with the appropriate MAPEI
cementitious or epoxy grouts, available in a
variety of different colours.
Expansion joints must be sealed with the
special MAPEI sealants.
SET TO LIGHT FOOT TRAFFIC
Floors are set to light foot traffic after
12 hours.
READY FOR USE
Surfaces are ready for use after 7 days.
Cleaning
Tools, buckets and clothes can be easily
cleaned with alcohol before hardening sets in.
Hardened Keralastic and Keralastic T can
be cleaned mechanically or with Pulicol 2000.
CONSUMPTION
%RQGLQJRIFHUDPLFVDQGVWRQHPDWHULDO
– Mosaics and small
size tiles (trowel No. 4):
2.5 kg/m²
– Normal size tiles
(trowel No. 5):
3.5 kg/m²
– Large size tiles, marble,
stones (back buttering):
5 kg/m²
PACKAGING
Keralastic and Keralastic T are available in
double metal drums of:
NJNJPŵFRPSRQHQW$NJPŵ
FRPSRQHQW%
NJNJPŵFRPSRQHQW$NJPŵ
FRPSRQHQW%
STORAGE
Keralastic and Keralastic T are stable for
at least 24 months when stored in sealed
GUXPV&RPSRQHQW%KDUGHQHUPXVWEH
stored in warm place to avoid crystallisation
GXULQJFROGZHDWKHUDWOHDVWDWƓ&
Should crystallisation occur, re-dissolve
by warming before use. Stir the product
before use.
TECHNICAL DATA (typical values)
In compliance with:
– European EN 12004 as R2, R2T
– ISO 13007-1 as R2, R2T
PRODUCT IDENTITY
component A
component B
Consistency:
WKLFNSDVWH
IOXLGOLTXLG
Colour:
Keralastic
Keralastic T
white - grey
white - grey
straw transp.
straw transp.
Density (g/cm³):
Keralastic
Keralastic T
1.50
1.56
0.93
0.93
97
100
800000
(# F - rpm 2.5)
1800000
(# F - rpm 2.5)
26
(# 1 - rpm 50)
46
(# 1 - rpm 50)
Dry solids content (%):
Brookfield Viscosity (mPa·s):
Keralastic
Keralastic T
Installing Carrara
marble on wooden
substrate with White
Keralastic
APPLICATION DATA (at +23°C and 50% R.H.)
Mix ratio by weight:
FRPSRQHQW$FRPSRQHQW% Consistency of mix:
very viscous
Density of mix (kg/m³):
Keralastic
Keralastic T
1450
1520
Brookfield Viscosity (mPa·s):
Keralastic
Keralastic T
400,000 (# F - rpm 5)
1,250,000 (# F - rpm 2.5)
Pot life:
30-40 minutes
Application temperature range:
IURPƓ&WRƓ&
Open time (according to EN 1346):
50 minutes
Adjustability time:
90 minutes
Setting time:
– initial:
– final:
6 hours
8 hours
Set to light foot traffic:
12 hours
Ready for use:
7 days
Green “Alpi” marble
flooring in the Rolex
building hall
(Bienne - Switzerland)
FINAL PERFORMANCES
Shear adhesion strength according to EN 12003
(N/mm²):
– initial shear adhesion strength:
– shear adhesion strength after water immersion:
– shear adhesion strength after thermal shock:
2.6
2.0
2.4
Resistance to ageing:
high
Resistance to solvents and oils:
good
Resistance to acids and alkalis:
good
Resistance to temperature:
IURPşƓ&WRƓ&
Deformability:
highly deformable
An example of an
installation of ceramic
or marble on a metal
structure (stairs)
All relevant references
for the product
are available upon
request and from
www.mapei.com
SAFETY INSTRUCTIONS FOR PREPARATION
AND INSTALLATION
Keralastic and Keralastic T component A are irritant for
the eyes and skin.
Keralastic and Keralastic TFRPSRQHQW%DUHFRUURVLYH
and may cause serious burns. They are also harmful if
LQKDOHG%RWKFRPSRQHQWVRIKeralastic and Keralastic T
may cause sensitisation in those subjects sensitive to such
substances. KeralasticFRPSRQHQW%LVDOVRKDUPIXOZKHQ
in contact with the skin.
When applying the product, we recommend the use
of protective gloves and goggles and to take the usual
precautions for handling chemical products. If the product
comes into contact with the eyes or skin, wash immediately
with plenty of clean water and seek medical attention.
Keralastic and Keralastic TFRPSRQHQWV$DQG%DUHDOVR
KD]DUGRXVIRUDTXDWLFOLIH'RQRWGLVSRVHRIWKHVHSURGXFWV
in the environment.
For further and complete information about the safe use of
our product please refer to our latest version of the Material
6DIHW\'DWDVKHHW
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WARNING
Although the technical details and recommendations
contained in this product data sheet correspond to the best
of our knowledge and experience, all the above information
must, in every case, be taken as merely indicative and
subject to confirmation after long-term practical application;
for this reason, anyone who intends to use the product
must ensure beforehand that it is suitable for the envisaged
application. In every case, the user alone is fully responsible
for any consequences deriving from the use of the product.
Please refer to the current version of the Technical Data
Sheet, available from our website www.mapei.com
122-1-2014
Waterproofed bath-tub
and shower
Any reproduction of texts, photos and illustrations published
here is prohibited and subject to prosecution
352'8&721/<)25352)(66,21$/86(
®
BUILDING THE FUTURE
9
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Two-part epoxypolyurethane adhesive
for rubber, PVC and
linoleum flooring
WHERE TO USE
Interior and exterior use. Bonding of rubber, PVC,
textile, needlepunch, and linoleum flooring, polystyrene
and polyurethane panels, fibrous concrete, wood,
sheet-metal, and plastic laminates.
Some application examples
Adesilex G19 is an extremely strong and flexible
all-purpose adhesive especially recommended for
non-absorbent or moisture-sensitive surfaces.
Adesilex G19 is used for bonding:
• rubber flooring tiles or sheet (with smooth back,
textured back, radial rubber tiles) in interiors and
exteriors subject to heavy traffic;
• rubber flooring for athletic complexes, even on asphalt
bases (e.g. tracks);
• synthetic grass;
• homogeneous or composite vinyl or PVC foam backed
flooring;
• semiflexible vinyl flooring;
• textile, needlepunch, tufted and woven flooring for
exterior installations;
• rubber and PVC floors over existing flooring;
• sandwich panels for prefabricated movable walls in
polystyrene, expanded polyurethane, fibrous concrete,
wood, composite board, metal sheeting, etc.;
• tack strip installation for stretching carpet
OVER
cement screeds, asphalt and non-absorbent flexible or
moisture-sensitive bases (metal sheets, plastic
laminates, fibrous concrete, rubber, PVC, wood, existing
ceramic tiles).
TECHNICAL CHARACTERISTICS
Adesilex G19 is a two-part adhesive composed of an
epoxy-polyurethane polymer, part A, and a special
hardener, part B.
Mixing the parts carefully forms a uniformly coloured
paste that is easily applied with a notched trowel.
After hardening in approx. 24 hours solely through
chemical reaction and without shrinkage, Adesilex G19
becomes flexible, resistent to moisture, water, heat and
atmospheric agents, with high bonding characteristics
on almost all materials commonly used in construction.
RECOMMENDATIONS
• Do not install on substrates subject to rising damp
(always place a vapour-proof membrane between the
ground and the screed).
• Do not install on damp concrete (residual moisture
must be no higher than 3.0%).
• Do not install on fresh asphalt (wait at least 20 days).
• Do not install on bituminous surfaces which might
bleed oils.
[sche2] 252_adesilex g19_gb (12.02.2008 - 4ª Bozza/Ciano/Stampa)
19
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• Do not use Adesilex G19 at temperatures
below +10°C or above +30°C.
Do not use at temperatures below +10°C
because setting time will be too long.
• Do not use on curved surfaces or on stairs
if the flooring is unable to maintain perfect
contact with the substrate until the
adhesive has set (use Adesilex VZ,
Adesilex LP or Ultrabond Aqua-Contact
applied to the back of the floor covering).
N.B. The ratio of resin (part A) to catalyst
(part B) is strictly determined. Any
modification to the dosage will interfere
with airing of the adhesive.
• Do not use Adesilex G19 for thin flooring
which may show adhesive ribs (use
Adesilex G20 self-levelling polyurethane
adhesive).
APPLICATION PROCEDURE
Preparing the substrate
Substrates must be thoroughly dry,
absorbent, level, resistant to compression
and tensile stress, free from dust, loose
particles, cracks, paint, wax, oil, rust, traces
of gypsum and materials which may interfere
with bonding.
The building regulations must be followed for
the relevant country.
Spreading
Adesilex G19 with a
notched trowel
The moisture content must be as follows: for
cement substrates, a maximum of 2-2.5%;
for gypsum or anhydrite based substrates,
a maximum of 0.5%.
It is essential to make sure there is no rising
damp present.
Floating screeds over layers of insulation and
screeds over bare ground must be isolated
by a vapour barrier.
When repairing cracks and crazing,
consolidating screeds, forming fast-drying
screeds, or levelling uneven screeds is
required, consult the MAPEI catalogue for
substrate preparation products or the
Technical Assistance Department.
External surfaces can be levelled with
Planicrete mixed with suitably graded sand
and cement or with Adesilex P4.
For exterior asphalt surfaces, use either
Adesilex G19 or Adesilex G20.
Installing rubber
flooring with
Adesilex G19
Laying PVC on a non
absorbent substrate
with Adesilex G19
In special cases and for small imperfections
in the substrate Adesilex G19 can be used
as a smoothing compound. Install the flooring
with Adesilex G19 as soon as the smoothing
layer is set sufficiently to take light foot traffic.
Acclimatisation
Before beginning the installation, ensure that
the adhesive, the floor or wall covering and
the substrate are acclimatised to the
prescribed temperature.
Spreading the adhesive
The choice of trowel depends on the back
of the flooring to be installed: for smooth
back use MAPEI trowels No. 1 and No. 2.
For textured backings use trowels No. 3 or
No. 4 (follow the flooring manufacturer’s
instructions).
Apply the adhesive evenly and on as much of
the surface that can be covered with flooring
in approximately 60 minutes, depending on
the ambient temperature and that of the
substrate.
Installing the floor-covering
Follow the installation instructions given
by the floor covering manufacturer.
Floor covering tiles or sheets must be applied
onto the Adesilex G19 while still fresh, within
1 hour at +23°C, and smoothed from the
center outward to ensure complete contact
and to remove entrapped air.
When the flooring is uneven, the deformed
sections, joints and ends must be weighted
down (with sandbags or other) until the
Adesilex G19 is set (12 to 24 hours).
Special care must be taken in exterior
installations at high temperatures or extreme
temperature differentials (install at the coolest
time of day).
For thick flooring in sports complexes and
synthetic grass, Adesilex G19 can be used
to bond sheets edge to edge.
Flooring bonded with Adesilex G19 is
sufficiently set to take light foot traffic in
approx. 12 to 24 hours. Final setting takes
place in approx. 3 days at an ambient
temperature of +23°C.
The setting time of Adesilex G19 at various
temperatures is as follows:
Temperature in °C
Hours
30 25 20 15 10 5
4 6 8 1 20 36
The floor and wall covering must be removed
from packaging several hours before
installing; rolls must be freely laid or at least
loosened to permit acclimatisation and
reduction of tension produced by packaging.
CONSUMPTION
Consumption varies, depending on the
evenness of the substrate, the type of
backing, and the trowel used:
with MAPEI 1 trowel: 400 to 500 g/m2;
with MAPEI 2 trowel: 500 to 600 g/m2;
with MAPEI 3 trowel: 600 to 800 g/m2;
with MAPEI 4 trowel: 800 to 1000 g/m2.
Mixing
The two parts of Adesilex G19 are available
in pre-measured proportions:
component A, 9.4 parts by weight;
component B, 0.6 parts by weight.
Cleaning
Adesilex G19 can be cleaned from flooring,
tools, hands and clothing with alcohol before
the hardening reaction occurs. After
hardening, it can only be removed
mechanically or with Pulicol.
Mixing must be carried out with a mechanical
stirrer until a homogeneous paste is obtained.
Setting time and pot life are closely related to
the ambient temperature (see Table).
Colours
Adesilex G19 is available in beige, red,
green, and black.
Special colours can be requested (min. 600 kg).
TECHNICAL DATA (typical values)
PRODUCT IDENTIFICATION
component A
component B
Consistency:
thick paste
fluid liquid
Colour:
beige, red, green, black
Density (g/cm3):
1.5
0.92
Dry solids content (%):
97
84
Brookfield viscosity (mPa • s):
300,000
(E rotor - 2.5 rpm)
30
(1 rotor - 5 rpm)
Storage:
Adesilex G19 is stable for at least 24 months if
containers are well sealed. The catalyst, Part B,
must be kept in heated areas to prevent
crystallisation at low temperatures, in which case it
must be thawed before using.
Hazard classification according to EC 1999/45:
irritant
corrosive, dangerous
to the environment
Before using refer to the “Safety instructions for
preparation and application” paragraph and the
information on the packing and Safety Data Sheet
Customs class:
3506 99 00
Installing PVC with
Adesilex G19
APPLICATION DATA (at +23°C - 50% R.H.)
Mixing ratio:
component A : component B = 94 : 6
Brookfield viscosity of mix (mPa • s):
180,000
(7 rotor - 10 rpm)
Density of mix (kg/cm3):
1,450
Pot life:
50 to 60 minutes
Application temperature range:
+10°C to +30°C
Open time:
1 hour
Adjustment time:
90 minutes
Initial setting:
8 hours
Final setting:
9 hours
Set to light foot traffic:
after 12 to 24 hours
Ready for use:
after 3 days
FINAL PERFORMANCE DATA
Resistance to moisture:
excellent
Resistance to ageing:
excellent
Resistance to oils and to solvents:
good
Resistance to acids and to alkali:
good
Flexibility:
yes
Stripping strength at +90°C in compliance with
EN 1372 standards after 14 days at +23°C (N/mm):
rubber: > 3 (breaking point)
PVC: > 3 (breaking point)
Installation of synthetic
grass flooring with
Adesilex G19 - S.Siro
Stadium - Milan - Italy
All relevant references
for the product are available
upon request and from
www.mapei.com
PACKAGING
Adesilex G19 is available in 10 kg, 5 kg, and
2 kg units.
STORAGE
Under normal conditions and in its original
unopened packaging Adesilex G19 is stable
for at least 24 months.
SAFETY INSTRUCTIONS FOR
PREPARATION AND APPLICATION
Adesilex G19 component A is irritant to the
eyes and skin.
Adesilex G19 component B is corrosive and
harmful if in contact with the skin or
swallowed. Both components can provoke
sensitivity in those who are susceptible to
such a complaint if in contact with the skin.
Use protective clothing, suitable gloves and
protect eyes and face. In case of contact with
eyes or skin, wash immediately with water. In
case of swallowing or serious reactions
consult a doctor. Use in well ventilated areas.
Both components are dangerous to aquatic
organisms; avoid release to the environment.
For further information refer to the Safety
Data Sheet.
HK (06/2012)
19
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WARNING
Although the technical details and
recommendations contained in this report
correspond to the best of our knowledge and
experience, all the above information must, in
every case be taken as merely indicative and
subject to confirmation after long-term
practical applications; for this reason, anyone
who intends to use the product must ensure
beforehand that it is suitable for the envisaged
application. In every case, the user alone is
fully responsible for any consequences
deriving from the use of the product.
VOLATILE ORGANIC COMPOUND
(VOC) LEVEL
Type of Regulated Adhesives under the Air
Pollution Control (Volatile Organic
Compounds) Regulation of Hong Kong:
[Rubber Flooring Adhesives]
VOC content (ready to use) not exceeding
30 g/litre
252-2-2008
Track at Olympic
Stadium in Rome:
rubber installed with
Adesilex G19
Any reproduction of texts, photos and illustrations published
here is prohibited and subject to prosecution
PRODUCT FOR PROFESSIONAL USE.
®
AKEPOX® 5010
Technical Instruction Sheet
Characteristics:
Page 1 of 3
AKEPOX® 5010 is a gel-like, two-component adhesive, is free of solvents, is
based on epoxy resins and has a cycloaliphatic polyamine hardener.
The product is characterised by the following properties:
- it has a very neutral colour
- little yellowing
- easy measuring and mixing by use of cartridge system
- because of it’s gel-like consistency it has a high creep strength
- during hardening there is very little shrinkage, and therefore minimal tension
within the adhesive joint
- the bonding are very weather resistant
- can be excellently coloured with AKEPOX® colour pastes
- the adhesive layer retains it’s from well
- it’s tendency to fatigue is slight
- it has a very high stability in contact with alkalis and is therefore very suitable
for bonding with concrete
- because it is free of solvents, it is especially suitable for bonding materials
which are impermeable to gas
- it is suitable for bonding load-bearing constructional elements
- it adheres well to stone even if it is slightly damp
- it is suitable for bonding materials which react in contact with solvents (e.g.
polystyrene, ABS)
- after being hardened the product is harmless to health upon contact with food
products – certified by the “LGA Nürnberg”
Field of Application:
AKEPOX® 5010 is mainly used in the stone-working industry for the weatherresistant bonding and glueing of natural stone (marble, granite) as well as artificial stone or building materials (terrazzo, concrete). By means of the application
of high-quality raw materials it was possible to develop a system which hardly
yellows. It is thus possible to use it in combination with light-coloured or even
white natural stone without the usual intensive yellowing of conventional epoxyresin systems. Because of it’s supple, gel-like consistency the product has a
high creep strength on vertical surfaces. It is nevertheless possible to attain thin
adhesive joints. Other materials can also be glued with AKEPOX® 5010, e.g.
plastics (hard PVC, polyester, polystyrene, ABS, polycarbonates), paper, wood,
glass and many other materials. AKEPOX® 5010 is not suitable for the gluing of
polyolefins (polyethylene, polypropylene), silicones, hydrocarbon fluorides (Teflon), soft PVC, soft polyurethane and butyl rubber.
Instructions for Use:
A. Product in cans
1. Contact surfaces must be thoroughly cleaned and lightly abraded.
2. Two parts (by weight or volume) of component A are to be thoroughly mixed
with one part of component B until a homogeneous colour is attained.
3. A coloration is possible by adding AKEPOX colour pastes up to a maximum
of 5 % of the total volume.
4. The mixture remains workable for ca. 20 – 30 minutes at 20° C. After ca. 6 –
8 hours (20° C) the bonded parts can be transported, after 12 – 16 hours (20°
C) they can bear loads and be tooled. The maximum strength is reached after
7 days (20° C).
5. Tools can be cleaned with AKEMI’s Nitro Dilution.
6. Warmth accelerates and cold retards the hardening process.
AKEPOX® 5010
Technical Instruction Sheet
Page 2 of 3
B. Cartridge System
1. Thoroughly clean and slightly roughen surfaces to be bonded.
2. Remove the clasp from the cartridge and put the cartridge in the gun; work
the grip until material emerges from both openings; then eventually screw up
the mixing nozzle.
3. AKEPOX® Colouring Pastes can be added up to max. 5 %.
4. The mixture remains workable for approx. 20-30 min (20°C). After 6-8 hours
(20°C) the bonded parts may be moved, after 12-16 hours (20°C) approx.
they may be further processed. Max. stability after 7 days (20°C).
5. Tools can be cleaned with AKEMI Nitro-Dilution.
6. The hardening process is accelerated by heat and delayed by cold.
Special Hints:
- The optimal mechanical and chemical properties can only be attained by adhering to the exact mixing proportions; excess of component A or B has the
effect of a plasticizer and can cause discolouration of the marginal area.
- Single-Mix cartridges are not suitable for compressed-air guns or guns with
mechanical pistons.
- Use AKEMI Liquid Glove to protect your hands.
- Component A and B should be extracted with separate spatulas.
- The adhesive is no longer to be used of, if it has already thickened or has
jellied.
- The product is not to be used at temperatures bellow 10° C because it will
then
insufficiently harden.
- At constant temperatures above 50° C the hardened adhesive is inclined to
yellow.
- The hardened adhesive can no longer be removed by means of solvents. This
can only be achieved mechanically or by applying higher temperatures (>
200° C).
- If the adhesive has been correctly worked it presents no hazard to health
when the hardening process is completed.
- The A-component tends slightly to crystallise (honey effect). The product can
be made workable again by warming it.
- The stability of the bonding is highly dependent upon the natural stone which
is to be bonded.: Silicate-bound stones react better than carbonate-bound
stones.
Safety Measures:
see EC Safety Data Sheet
Technical Data:
1. Component A: colour:
density:
colourless – slightly yellow, milky
ca. 1.17 g/cm³
Component B: colour:
density:
colourless – slightly yellow, milky
ca: 1.13 g/cm³
2. Working time:
a) a mixture of 100 g of component A + 50 g of component B
at 10° C: 60 - 70 minutes
at 20° C: 20 - 30 minutes
at 30° C: 15 - 20 minutes
at 40° C: 5 - 10 minutes
AKEPOX® 5010
Technical Instruction Sheet
Page 3 of 3
b) at 20° C with varying amounts
20 g of component A
50 g of component A
100 g of component A
300 g of component A
+ 10 g of component B:
+ 25 g of component B:
+ 50 g of component B:
+ 150 g of component B:
35 – 45 minutes
25 – 35 minutes
20 – 30 minutes
15 – 25 minutes
3. The hardening process (Shore D hardness) of a 20 mm layer at 20° C
3 hours
--
4 hours 5 hours 6 hours 7 hours 8 hours
30
51
67
74
76
24 hours
81
4. Mechanical properties
bending strength (DIN 53452):
tensile strength (DIN 53455):
modulus of elasticity:
5. Chemical Resistance
Water absorption DIN 53495
Sodium Chloride Solution 10%
Salt Water
Ammonium 10%
Soda Lye 10%
Hydrochloric acid 10%
Acetic acid 10%
Formic acid 10%
Petrol
Diesel oil
Lubricating oil
6. Shelf life:
Notice:
60 70 N/mm²
30 40 N/mm²
2500 - 3000 N/mm²
< 0.5 %
stable
stable
stable
stable
stable
conditionally stable
conditionally stable
stable
stable
stable
1 year approx. if stored in cool place free from frost in its
tightly closed original container.
The above information is based on the latest stage of technical progress It is to
be considered as a non-binding hint and does not release the user from a performance test, since application, processing and environmental influences are
beyond our realm of control.
TIS 06.08
AKEMI GmbH . Lechstraße 28 . D-90451 Nürnberg . Tel. +49(0)911/64296-0 . Fax +49(0)911/644456
www.akemi.com