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Natural StoneProfessional fi xing and grouting
Whatever your construction problem, whatever the structure you are
building, BASF Construction Chemicals has an intelligent solution to help
you be more successful.
Our market leading brands offer the widest range of proven technologies to
help you build a better world.
Emaco® - Concrete Repair Systems
MBrace® - Composite Strengthening Systems
Masterflow® - Precision and Structural Grouts
Masterflex® - Joint Sealants
Masterseal® - Coatings and Waterproofing
Concresive® - Crack Injection Resins
Conideck® - Hand and Spray applied Waterproof Membrane Systems
Coniroof® - PU Based Roofing Systems
Mastertop® - Decorative and Industrial Flooring Solutions
Ucrete® - Flooring Solutions for Harsh Environments
Glenium® - Superplasticizers
RheoFIT® - Waterproofing Admixtures
Masterkure® - Curing Compounds
Rheofinish® - Release Agents
MEYCO® - Shotcrete and Spraying Equipment
Micro-Air® - Air-entraining Agents
PCI® - Tile Fixing, Cement Underlays and Waterproofing Systems
Intelligent solutions fromBASF Construction Chemicals
Head Office BASF plc,Construction ChemicalsPO Box 4Earl RoadCheadle HulmeCheadleCheshireSK8 6QG
Tel: 0161 485 6222Fax: 0161 488 5220
www.basf-cc.co.ukwww.pci.uk.com
BASF plc,Construction Chemicals19 Broad Ground RoadLakesideRedditchWorcestershire B98 8YP
Tel: 01527 512255Fax: 01527 510299
www.basf-cc.co.ukwww.pci.uk.com
About BASFBASF is the world’s leading chemical company: The Chemical Company. Its portfolio ranges from chemicals, plastics, performance products and agricultural products to oil and gas. As a reliable partner BASF creates chemistry to help its customers in virtually all industries to be more successful. With its high-value products and intelligent solutions, BASF plays an important role in finding answers to global challenges such as climate protection, energy efficiency, nutrition and mobility. BASF posted sales of about 63.9 billion in 2010 and had approximately 109,000 employees as of the end of the year. BASF shares are traded on the stock exchanges in Frankfurt (BAS), London (BFA) and Zurich (AN). Further information on BASF is available on the Internet at www.basf.com or in its Social Media Newsroom at newsroom.basf.com.
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
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