Substrate preparation:
The substrate has to be compact, clean, free of grease, oil, laitance and any substances which compromise the adhesion of NOVACOL ULTRA GEL. The minimum tensile strength of the substrate must be at least 1,5 N/mm².
Existing ceramic, gres porcelain tiles, marble and stone coverings on floors and/or walls must be firmly attached to the substrate and free of laitance on their surface which may compromise adhesion. If required clean the coverings with appropriate detergent, depending on the type of dirt, like ALCALINE CLEANER or ACID CLEAN and rinse with plenty of water. Prior to the application of tiles a primer coat of PLANO CONTACT FAST should be applied.
Preparation of the mix:
Mix the content of a 25kg paper bag containing NOVACOL ULTRA GEL (25 kg) with 8 - 8,5 liters of clean and fresh water by means of appropriate electrical stirrer at low speed for at least 3 minutes, until a uniform mortar free of lumps is obtained. The mix has a pot life of 6 hours. During hot periods and in general, it is recommended to avoid direct sunlight exposure of the materials (in powder or liquid form) before use, otherwise the working time is reduced.
If required, sand (THASSOS MIX) can be added up to 50% by weight without reducing workability and remaining in category C2. In this case the required amount of water is calculated on the amount of NOVACOL ULTRA GEL. Depending on the desired workability 37.5 kg mixture (25 kg NOVACOL ULTRA GEL + 12.5 kg THASSOS MIX 0 - 2) require 8 - 8.5 kg water.
Application:
The tiles are placed on the still fresh adhesive bed, by applying firm pressure, in order to ensure full contact between the tiles and the adhesive. The open time of NOVACOL ULTRA GEL in normal temperature and humidity conditions is 30 minutes. Unfavorable weather conditions like contact with strong direct sunlight, drying and/or hot wind or a very absorbent substrate may reduce open time significantly. For this reason it is important to check if the adhesive has formed a superficial 'skin'. If such incident occurs, remove the adhesive from the substrate and reapply it, before applying the tiles. Small corrections must take place 20 minutes after tile application.
Grouting:
Grouting can take place 12 – 24 hours after tile application. For large size tiles this waiting time might be prolonged. For grouting joints up to 10mm width it is recommended to use NOVAGROUT F. For rectified tiles or when the requirement is very smooth grout surface, NOVACOLOR GLASS can be used. For wide joints of 5 – 20mm NOVAGROUT G can be used. In areas where resistance to strong chemicals is required like in example swimming pools or industrial floors it is recommended to use the epoxy grout NOVAGROUT EPOXY. For additional information refer to the Technical Data Sheets of the relevant products.
Recommendations:
Avoid using:
- In cases where the substrate and environmental temperature is less than +5°C or higher than+35°C
- On friable or not properly cured substrates
- In a thickness higher than 10mm
- For bonding humidity sensitive marble and natural stone
- Over not absorbent substrates without appropriate primer
- Over existing expansion joints
- On substrates like polyurethane, acrylic and similar paint or coatings (use NOVACOL 2K ELASTIC)
- On PVC, asphalt membranes and in general materials which polymerize in the long run
- Inside swimming pools without tiles
- Under direct sunlight and/or strong wind
Also note the following:
- Never exceed the maximum recommended quantity of mixing water
- Protect the tiled surface from rain and frost for the first 24 hours
- Do not add cement, lime, gypsum or other binders or substances which may affect the mortar characteristics
- For gypsum or cementitious boards or highly absorbent substrates NOVAPRIMER is as primer required
- For metal or wooden surfaces, it is suitable only for internal use and with a suitable primer
- For tiles of total surface over 900 cm² the double-spreading (buttering) technique of adhesive is always recommended
- If sand other than THASSOS MIX is used, the water requirement and final performance may vary
- Application should be performed by professional skilled workers
Cleaning:
Tools, buckets, tiles, etc. can be cleaned with fresh and clean water as long as, NOVACOL ULTRA GEL is still fresh. After hardening occurs, cleaning can take place by mechanical means.
PLANOCOLOR GRANULATES S 70 | 13 kg |
E. Application of the mix and surface treatment:
The mix is applied by means of a flat spatula, trowel or suitable spray systems, depending on the final composition of the mixture, on
During levelling - smoothing process, apply adequate pressure on the fresh mortar surface, in order to compress the material to its dedicated thickness and remove air bubbles that might have been 'trapped' in the mix during the stirring process. Then, flatten the surface using appropriate metal spatula or suitable levelling tool.
If during the levelling process, bumps due to air trapped inside the mortar during the mixing process, occur then by means of appropriate stick or trowel, ‘break’ them in order to allow to the trapped air to ‘escape’. Levelling of the layer should take place while the mortar is still fresh.
The application thickness depends on the maximum grain dimension of the granulates used, the minimum layer thickness is 2 – 3 times the maximum grain size of the granulates.
The mortar must be applied under normal conditions within 1 hour after mixing. After this period do not try to ‘soften’ the mix by adding water
Low temperatures extend open time of the mix while high temperatures drastically reduce it. The temperature of the mixing water, as well as the surface temperature of the substrate might also affect the workability.
It is recommended to avoid long sunlight exposure of the materials before use, otherwise the working time is reduced drastically.
Important: In general, the terrazzo or micro pebble coverings created by the use of the hydraulic binders NOVACEM CREATIVE or NOVACEM CREATIVE FLOOR encounter the same limitations of application of concrete and cement based mortars.
E1. Creation and protection of a surface with exposed pebbles:
After the mortar leveling and within 30 minutes from application, spray the entire surface with a suitable surface retarder such as PLANOCOLOR CRT 052. In case of rain during the waiting period required for the surface retarder to act, remove the PLANOCOLOR CRT 052 layer without waiting.
The pebbles can be exposed by three methods:
- By means of suitable Scotch-Brite type sponge and water in 2 to 6 hours depending on jobsite conditions. This methodology is primarily used on small vertical surfaces. If during the process of removing the cementitious material to expose the pebbles, pebbles are also removed, allow longer period for the surface to dry.
- By means of high-pressure waterjet (120-160 bar) 12 to 24 hours after the application of the retardant depending on jobsite conditions. If during the process of removing the cementitious material to expose the pebbles, pebbles are also removed, allow longer period for the surface to dry.
- By use of suitable rotary antique brush with or without water 24 to 48 hours upon application of the retardant depending on jobsite conditions. The type of antique brush is often number 120 or 180 but this depends on the type of application and requested texture finish.
In case that the surface retardant PLANOCOLOR CRT 052 is not used, the three methodologies can be applied, however the waiting times are significantly reduced, subject to jobsite conditions. In such cases, continuous supervision is required to ensure the well-timed initiation of the chosen process.
If required and regardless the chosen system used, the acidic detergent ACID CLEAN TURBO can be used to chemically assist the process.
Upon completion of the exposure of the pebbles and as soon as the surface dries (2-24 hours) it is recommended to apply a hardener/densifier such as PLANOFINISH CH PLUS. The use of this particular densifier reduces cracks development and is highly recommended in outdoor applications and swimming pools.
The last state of the process is the application of surface protection by using a suitable waterproofing agent, depending on the requirements of the application:
- For an application inside water tanks, fountains, swimming pools and in permanent water immersion, it is recommended to apply only the densifier PLANOFINISH CH PLUS and not to apply any type of waterproofing agent.
- In horizontal or vertical surfaces where the design intent doesn’t require color enhancing of final look, it is recommended to apply one or two layers of the solvent based waterproofing agent PROTECT 300 S, subject to the absorbency of the surface.
- If color enhancing of the pebbles and/or the binder mortar is required, the application of WET PLUS S is recommended in one or two layers.
- Subject to the requirement of the application WET PLUS S can be applied in combination with PROTECT 300 S. Regardless of which of the two waterproofing agents is used as first or second layer, the applicator should ensure that excess of product at the surface is removed during the installation process.
- For indoor coverings of walls & floors and for cases where the use of a solvent free waterproofing material is required PROTECT 200 can be applied.
In any case, the application of any chosen waterproofing agent is performed, only when the humidity of the micro-pebble covering is less than 4%.
E2. Creation and protection of a polished terrazzo surface:
The mechanical grinding and polishing methodology of creating and protecting a terrazzo surface depends on the conditions and scope of each application. Indicative we refer to the following:
- The degree of polishing. For example, outdoor application or swimming pool walls might have a requirement for a ‘honed’, anti-slip final surface.
- The chosen polishing system (wet or dry polishing or with or without the use of chemical process of crystallization)
- design intent requirements such as the prevention of using solvent based products.
- the composition of the terrazzo mix
The polishing process should be undertaken by professional team with suitable equipment for the chosen application.
A typical process of mechanical grinding/polishing is the following:
- Subject to the degree of polishing required the use of metal or resin polishing disk with indicative sequence 24 /50/100/150/200/320/400/800/1500/3000 etc.
- The use of PLANOFINISH CH surface densifier will assist the polishing process.
- For filling pinholes occurred during mechanical grinding, the cement based mortar NOVACEM MF (for indoor/outdoor application) or the epoxy filler paste PLANOFINISH CRYSTAL (for indoor application only) can be used.
- Depending on the desired degree of polishing level, the application of the following waterproofing agents is recommended, subject to a covering humidity content of less than 4%:
- For coverings with lower degree of polishing the use of PROTECT 300 S is recommended.
- For coverings with higher degree of polishing and reduced absorption the use of PROTECT 900 S is recommended.
- In cases, where color enhancing of the pebbles and/or the binder mortar is required, the application of WET PLUS S is recommended.
- For indoor applications that require a high degree of polishing level and protection, the application of PLANOFINISH HP is recommended as long as the surface is dry and without any standing water. It is applied by means of suitable high speed rotary engine (1500-2000 rpm) equipped with suitable felt pad:
- Upon application of the chosen waterproofing agent.
- Or upon completion of the mechanical polishing process.
E3. Surface treatment and protection using solvent-free products:
- For pinholes occurring during mechanical grinding, apply as a filler material NOVACEM MF.
- Apply the solvent-free waterproofing material PROTECT 200 up to a maximum polishing grit of no. 400 to ensure penetration to the surface and avoid the creation of a surface membrane.
- For indoor applications that require a high degree of polishing level and protection, the application of the self-polishing surface action sealant PLANOFINISH HP is recommended as long as the surface is dry without any standing water. It is applied by means of suitable high speed rotary engine (1500-2000 rpm) equipped with suitable felt pad:
- upon completion of mechanical polishing
- or upon completion of waterproofing with PROTECT 200.
In any case the application of any chosen waterproofing agent is performed when the humidity of the covering is less than 4%. This is applicable to both solvent free and solvent based waterproofing agents.
Expansion Joints:
In any case, existing expansion joints or control joints on the substrate must be followed by the final surface covering. The location of each expansion /control joint depends on the use of the surface, the geometry and the location.
Control joints must be provided on each surface change (wall-to-wall and wall-to-floor joints, depth changes in swimming pools) and every 4-5 running meters in length, with a maximum ratio between long and short side 2:1.
These joints are filled with a flexible sealant suitable either for indoors/outdoors such as the NOVAMIX PU 500 or with a sealant suitable for permanent immersion in water, such as NOVACOLOR HNR. In any case it is recommended to pre-coat the joints with an epoxy primer such as PRIMER NR 2K.
Prefabricated joint profiles of suitable cross-section and composition can be used, depending on the design intent requirements.
Maintenance of micro pebble/terrazzo surface:
The micro pebble/terrazzo coverings are surfaces that contain 65-75% of pebbles that often have different physical and chemical properties that affect absorbency or strength to resist chemical and mechanical stresses.
The chosen surface finish (anti slip micro pebble covering with exposed aggregate or polished terrazzo surface) significantly affects daily and special maintenance which is why
- the type of application and
- the specific use
should be carefully considered at the design stage.
Indicative recommendations for daily and special maintenance of for micropebble/terrazzo surfaces can be found below:
- For day-to-day cleaning process it is recommended the neutral detergent
- Oily stains, rubber wheel marks, residues of smoke in walls can be cleaned by the alkaline based detergent ALCALINE CLEANER.
- Varnishes, synthetic stains, paints are cleaned by CLEANCOLL or CLEANCOLL SP
- Cementitious residues rust and other inorganic hard pollutants are cleaned with an acidic detergent such as ACID CLEAN, ACID CLEAN TURBO. These might be diluted in water subject to requirement.
Recommendations:
- Apply over a structural stable and well prepared substrate
- Do not add water or additives once the mix starts to set
- Do not overlap existing expansion or control joints of the substrate
- Do not mix NOVACEM CREATIVE or NOVACEM CREATIVE FLOOR with gypsum, cement, resins, latex or other binders. Mix only with compatible to cement, aggregates and water
- Do not mix with dolomite aggregates
- Do not apply upon deformable substrates or surfaces subjected to vibration
- Do not apply upon non-absorbent substrates such as metal, glass, old ceramic tiles and mosaics without applying appropriate primer.
- Permanent water immersion after 7 – 10 days. In this case, the use of varnish or other protective coating is not recommended, with the exception of the hardener/densifier PLANOFINISH CH PLUS which helps on cracking prevention. Although optional, the application of PLANOFINISH CH PLUS is highly recommended for outdoor and demanding applications
- In case where specific color is required it is recommended to mix with NOVACOLOR CARBON or NOVACOLOR OXIDE or NOVACOLOR DESIGN or NOVACOLOR UNIVERSAL in appropriate proportions. Keep in mind that pigments can discolor due to contact with strong floor or pool cleaners
- Do not apply when temperature of the substrate and environment is lower than +5°C and higher than +35°C
- The use of NOVACEM CREATIVE or NOVACEM CREATIVE FLOOR or PLANOCOLOR GRANULATES from different batches is not recommended
- Colored marble granulates may discolor in the long run, when applied inside swimming pools and areas cleaned with strong chemicals
- Application must be done by professional applicator
Refer to the Technical Data Sheets as well as the Safety Data Sheets of the products listed here.
Cleaning:
Tools used during the preparation and application can be cleaned with water while NOVACEM CREATIVE or NOVACEM CREATIVE FLOOR is still fresh. If hardening occurs, cleaning can be done only by mechanical means.
Legal Notice:
The technical data and recommendations included or listed are the outcome of laboratory measurements combined with our current knowledge and expertise. All information and specifications should in any case be considered as indicative. The Company makes every effort to ensure the accuracy of the information provided herein. Product specifications are subject to change without notice and may differ from product images. Due to printing and application procedures, the colors displayed here should be considered as indicative. In particular, variations in materials, substrates and on-site application conditions are such that no warranty can be given or implied reference to the suitability of the materials for trading or use for a particular purpose and conditions of any given project. Anyone interested in using the product must ensure beforehand that the product is suitable for the intended use and in any case, the user is solely responsible for any outcomes associated with the use of product. Among other things, the Company is not responsible for any normal wear or tear from environmental or any other unsuitable conditions. We reserve the right to revise or change the data herein without prior notice. Restrictions and disclaimers apply to the extent permitted by applicable law. The Company has a Technical Support Department, which has exclusive responsibility for providing technical advice and solutions, addressing relevant issues. Requests to the Technical Support Department are addressed and answered, only in writing. For the latest and valid version of the Technical Data Sheet, the user of the material must refer to our website www.novamix.gr.