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\ Crack-Resistant Mortar /
Crack-resistant mortar (anti-crack mortar) is a type of mortar made by mixing a crack-resistant agent (composed of polymer emulsion and additives), cement, and sand in a specific ratio with water. It is designed to withstand certain levels of deformation without cracking. When used in conjunction with mesh fabric, it achieves even better results.
Construction Methods:
1. Clean the wall surface of dust, grease, and debris to ensure it is clean and smooth.
2. Mix the mortar powder and water in a ratio of 1:0.3 using a mortar mixer or handheld mixer until thoroughly blended.
3. Apply the mortar to the wall using either a spot application or thin coat method, pressing firmly to achieve a smooth surface.
4. Application rate: 3-5 kg/m².
Construction Process:
1. Substrate Preparation: The surface of the insulation boards to be bonded should be as flat, clean, and firm as possible. If necessary, sand with coarse sandpaper. Press the insulation boards tightly together, and any gaps between the boards should be filled with insulation surface material. The surface should then be leveled with adhesive powder and expanded polystyrene particle insulation mortar.
2. Material Preparation: Add water directly and mix for 5 minutes until uniform.
3. Application: Apply the crack-resistant mortar with a stainless steel trowel onto the insulation boards, press the glass fiber mesh into the mortar, and level it. Overlap the mesh joints by 10 cm, ensuring the glass fiber is fully embedded. The fiber-reinforced surface layer should be approximately 2–5 mm thick.
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\ Adhesive Mortar /
Bonding mortar is a mixture of cement, quartz sand, polymer binder, and various additives, mechanically blended to uniform consistency. It is primarily used as an adhesive for bonding insulation boards and is also known as polymer insulation board bonding mortar. This bonding mortar is made from high-quality modified special cement, multiple high-performance polymers, and fillers through a unique composite process, offering excellent water retention and high bonding strength.
Main Features:
1. It has strong bonding properties with the base wall and insulation boards such as polystyrene boards.
2. It is water-resistant, freeze-thaw resistant, and has excellent aging resistance.
3. It is easy to apply and is a safe and reliable bonding material for insulation systems.
4. It does not slip or sag during application. It has excellent weather resistance, impact resistance, and crack-resistant properties.
Application Method:
1. Base requirements: The surface must be flat, firm, dry, and clean. New plaster layers must be fully cured and dried for at least 14 days before application (base surface flatness must be less than 2-5 mm per square meter).
2. Material preparation: Add water at a ratio of 25-30% of the material weight (water content may be adjusted based on the base surface and weather conditions), mix thoroughly, and use the mixed material within 2 hours.
3. The adhesive consumption for bonding polystyrene boards is 4-5 kg per square meter.
Depending on the wall’s flatness, either the full-surface bonding method or the spot-frame bonding method should be used to bond the polystyrene boards.
a. Full-surface bonding: Suitable for flat substrates with a flatness requirement of less than 5 millimeters per square meter. Apply the adhesive to the insulation board using a notched trowel, then bond the insulation board to the wall from bottom to top. Ensure the board surface is flat, and the joints are pressed tightly with no gaps.
b. Spot-frame bonding: Suitable for uneven substrates with unevenness less than 10 millimeters per square meter. Apply the adhesive evenly to the edges of the insulation board using a trowel, then distribute six adhesive points evenly across the board surface. The thickness of the adhesive application depends on the wall’s flatness. Then attach the board to the wall using the method described above.
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\ Insulation mortar /
Insulation mortar is a pre-mixed dry powder mortar made by mixing various lightweight materials as aggregate, cement as a binder, and some modified additives by the manufacturer. It is a building material used to construct insulation layers on building surfaces. Inorganic insulation mortar systems are fire-resistant and non-combustible. They can be widely used in high-density residential buildings, public buildings, large public spaces, flammable and explosive areas, and places with strict fire safety requirements. It can also be used for fire-resistant isolation zones to enhance building fire safety standards.
Performance Characteristics:
1. Inorganic insulation mortar has excellent thermal stability and chemical stability:
The inorganic insulation mortar insulation system is made from pure inorganic materials. It is resistant to acids and alkalis, corrosion-resistant, crack-resistant, non-peeling, highly stable, and does not age, ensuring a lifespan equal to that of the building structure.
2. Easy to apply with low overall construction costs:
The inorganic insulation mortar insulation system can be directly applied to rough walls, with the same construction method as cement mortar leveling layers. The machinery and tools used are simple. Construction is convenient, and compared to other insulation systems, it has the advantages of shorter construction periods and easier quality control.
3. Wide application range, preventing thermal bridges:
The inorganic insulation mortar material insulation system is suitable for various wall base materials and complex wall shapes. It is fully enclosed, seamless, and cavity-free, preventing thermal bridges. It can be used for external wall insulation, internal wall insulation, or both simultaneously, as well as roof insulation and thermal insulation layers for underfloor heating, providing flexibility for energy-saving system design.
4. Environmentally friendly and non-toxic:
The inorganic insulation mortar material insulation system is non-toxic, odorless, and free of radioactive pollution, posing no harm to the environment or human health. Its widespread use can also utilize industrial waste and low-grade building materials, offering excellent comprehensive environmental benefits.
5. High strength:
The inorganic insulation mortar material insulation system has high bonding strength with the base layer, making it resistant to cracking and hollow voids. This feature gives it a technical advantage over all other insulation materials currently available in China.
6. Fire-resistant and safe:
The inorganic insulation mortar material insulation system is fire-resistant and non-combustible. It can be widely used in high-density residential buildings, public buildings, large public spaces, flammable and explosive areas, and locations with strict fire safety requirements. It can also be used as a fire-resistant barrier to enhance building fire safety standards.
7. Excellent thermal performance:
The thermal storage capacity of inorganic insulation mortar systems is significantly higher than that of organic insulation materials, making them suitable for summer heat insulation in southern regions. With sufficient thickness, their thermal conductivity can be reduced to below 0.07 W/m·K, and thermal performance can be easily adjusted to meet mechanical strength requirements and actual functional needs, enabling application in various scenarios such as floors and ceilings.
8. Excellent mold prevention: It prevents energy transfer through thermal bridges and inhibits mold growth caused by condensation inside buildings.
9. Cost-effective: Replacing traditional double-sided interior and exterior plastering with an inorganic insulation mortar system using an appropriate formulation achieves an optimized solution in terms of both technical performance and economic efficiency.
10. Enhanced dispersible polymer powder, inorganic binding materials, high-quality aggregates, and additives with functions such as water retention, strength enhancement, thixotropy, and crack resistance are pre-mixed and dry-blended.
11. Excellent bonding strength with various insulation materials.
12. Good flexibility, water resistance, and weather resistance; low thermal conductivity, stable insulation performance, high softening coefficient, freeze-thaw resistance, and aging resistance.
13. Can be mixed with water on-site for convenient use; excellent breathability and moisture-wicking properties, providing both waterproofing and moisture-vapor permeability.
14. Lower overall construction costs.
15. Superior thermal insulation performance.
Construction methods:
1. The base surface must be free of dust, oil, and other contaminants that may affect adhesion.
2. In hot weather or when the substrate is dry and has high water absorption, moisten the substrate with water to achieve internal moisture and external dryness, with no standing water on the surface.
3. Mix the insulation system-specific primer at a water-to-cement ratio of 1:4–5 until uniform, then apply it to the substrate and pull into a sawtooth pattern, with a thickness of approximately 3 mm. Alternatively, a spray application method may be used.
4. Mix the insulation mortar with a ratio of adhesive powder to expanded polystyrene particles to water of 1:0.08:1 to form a paste. Ensure the mixture is thoroughly mixed with no lumps.
5. Apply the insulation mortar according to energy-saving requirements. For thicknesses over 2 cm, apply in multiple layers, with a minimum interval of 24 hours between coats. Spraying is also acceptable.
6. Apply the crack-resistant mortar over the insulation mortar with a thickness of 2 mm.
7. Apply alkali-resistant mesh fabric over the crack-resistant mortar.
8. Finally, apply another layer of crack-resistant mortar with a thickness of 2–3 mm over the alkali-resistant mesh fabric.
9. After the protective layer is completed, cure for 2–3 days (depending on temperature) before proceeding with the subsequent finish layer construction.