The subject of the invention is an adhesive and grouting mortar, in particular for ceramic tiles, containing Portland cement with a foamed glass content.

In recent years one can observe the trend of shortening the time of construction work. This is connected with improving its organisation but also with the change of materials used for construction work. In the case of finishing works, fitting ceramic elements plays a special role as for many years now it has been appreciated for its durability and aesthetic appeal. Mortars used for fitting ceramic tiles can be divided into ones used for installing the tiles and then the process of grouting takes place which significantly prolongs the process of installing the tiles. It makes it necessary to wait until the ceramic tiles have bonded with the wall and only then is it possible to apply the grout.

There are many known adhesives and mortars used for fitting ceramic tiles and so the Polish patent description PL.162319 describes a method of repairing defects consisting in applying a thin intermediate adhesive layer made of adhesive cement slurry modified with an epoxy set onto the cleaned and prepared surface of the bottom and the edge of the defect, and then onto this layer the final filling layer is applied made of known mortars or cement concretes, where the thickness of the final filling layer is usually a few centimetres. The adhesive cement slurry contains water and cement in the amount of up to 7,5 parts by weight of water to 25 parts by weight of cement, and additionally contains two modifying components A and B in the amount from 2,5 to 10 parts by weight of component A and from 2,5 to 10 parts by weight of component B to 25 parts by weight of cement, where component A is a 50% aqueous emulsion of resin and component B is a 50% aqueous suspension of a hardening agent.

Another patent application P.417020 describes a dry adhesive mortar, in particular for ceramic tiles, containing Portland cement. The dry adhesive mortar, in particular for ceramic tiles, contains 25 to 40 wt% of Portland cement, 55 to 72 wt% of quartz sand with grain size of up to 0,5 mm, 2 to 7 wt% of flour, favourably carbonate or silica flour with particle size of up to 0,1 mm, 0,3 to 8 wt% of bonding agent based on ethylene-vinyl acetate (copolymer), 0,2 to 0,8 wt% of hydroxypropyl ethylcellulose [HPMC] with the viscosity from 65 to 75 Pa x s, 0,5 to 0,8 wt% of calcium formate with particle size of up to 0,2 mm. The dry adhesive mortar after having been mixed with water can be used to join ceramic tiles with a thin layer, favourably with the thickness from 1 mm to 6 mm.

Another Polish patent application P.416358 describes a two-component adhesive mortar for ceramic facings to be used outside and inside as an adhesive, to form waterproof coating and as a filler for joints between elements of ceramic facings. The mortar contains Portland cement and water as well as silicate flour and quartz hydrophobized with alkoxy silanes in part A and a water dispersion of styrene acrylic polymer in part B. Part A of the mortar contains from 27% to 29% of Portland cement, from 14% to 20% of silicate flour, from 50% to 59% of quartz hydrophobized with alkoxy silanes, from 0,3% to 0,4% polypropylene fibres with fibre length of 3 mm, from 0,08% to 0,15% of hydroxyethylmethylcell ulose. Part B of the mortar contains from 81% to 87% of water dispersion of styrene acrylic polymer, from 13% to 19% of water and 0,3% of biocide, a mixture of isothiazoles.

The Polish patent application P.376805 describes a light adhesive mortar for gluing foamed polystyrene sheets in thermal insulation systems using the „light-wet" method, which contains a light mineral filler, favourably pearlite or mineral filler, favourably foamed polystyrene in the form of granules or beads with the diameter of 0,2-3 mm, favourably in the amount of 20-70 %vol.

A Chinese patent application CN110028295A describes a mortar that supports ECP wall panels and the method of its manufacture. The binder supporting the ECP wall panels consists of the following components in percentage by weight: 10-40% cement, 10-30% early strength cement, 30-75% medium and fine sand, 0,001-1% molecular polymer of cellulose ether, 0,01-2% engineering fibre, 0,1-10% expanding agent, 0-5% early strength agent for improving strength and 0,1-5% dehydrating agent. The mortar material supporting the wall panel according to the invention may effectively solve the problem of shrinkage of the existing drying mortar material and is comfortable and quick in construction as well as fast in forming. Generally speaking, the cycle of hardening of the cement slurry may be completed within 2-3 days after grouting, and the grouting material may be permanently formed to guarantee tight joining of the casting material and the concrete element, water-tightness and the impermeability of the grouting material improves, the durability of the grouting is also improved, the hardening cycle is shortened, the efficiency of the structure improves and the building cost is reduced. The method of preparing the grouting material is simple, the cost is low and construction is comfortable and quick.

European patent EP1609770 discloses a hydraulically bonding adhesive mortar comprising 10-70 wt.% hydraulic binder, 1-70 wt.% additives based on pozzolanic and/or latent hydraulic additives, 10-80 wt.% fillers, 0.01-5 wt.% polymer solvent based on unsaturated mono- and/or di-carboxylic acids or their derivatives and oxyalkylene glycol- alkenyl ethers, 0.01-15 wt.% redispersible polymer powder and/or plastic dispersion based on vinyl or acrylate polymers, 0.01-10 wt.% water retention agent, 0.01-5 wt.% other additives selected from accelerators, delayers, thickeners, dispersants, dye pigments, reducing agents, air pore formers and processing auxiliary agents and a balance of water.

In the so far applied solutions, the adhesive mortar for fitting ceramics or stone to walls and the grouting material for filling the space between tiles are used separately. In publications there may be patent applications found whose authors focused solely on the problem of fitting the tiles to the wall, i.e. how fast the tiles dry, and durability. There have also been solutions mentioning the noise damping function, which may be particularly useful in the case of bathrooms, where technical appliances such as washing-machines are installed, which may generate considerable noise during a 2-hours' washing cycle. As far as grout is concerned inventors focused on the colour-fastness, often their whiteness, which in turn causes considerable chemical aggressiveness due to the chemical substances used, often based on zinc. The use of two different preparations makes things more difficult for the workers, especially if there are different colours used in different rooms.

The technical problem is to create a mixture of components forming an adhesive and grouting mortar which is used to fit the ceramic material to the wall, but which is also used for grouting.

In the light of the existing state-of-the-art, the aim of the present invention is to overcome the abovementioned inconveniences and to deliver a mortar which can be also used as grout.

Quite unexpectedly it has turned out that a combination of foamed glass and Portland cement with lime, quartz sand, cellulose ether, trass meal and calcium stearate forms a composition which may be used both for fitting ceramic tiles and for grouting.

The essence of the invention is using a combination of Portland cement and adding foamed glass to the mortar which unexpectedly resulted in the mortar gaining hydrophobic properties and compressibility which allows it to be used as grout, while at the same time it does not lose the breaking strength necessary for gluing the ceramic elements to the base.

The adhesive and grouting mortar containing Portland cement, a filler in the form of quartz sand, additional substances such as hydrated lime, trass meal is characteristic in that it contains: - Portland cement in the amount from 20 to 30 wt%,

- hydrated lime in the amount from 1 to 10 wt%,

- quartz sand with grain size from 0,1 to 1,00 mm in the amount from 30 to 80 wt%,

- cellulose ether in the amount from 0,01% to 5 wt%,

- trass meal in the amount from 0,01% to 5 wt%,

- calcium stearate in the amount from 0,01% to 5 wt%,

- foamed glass with grain size of 0,25 to 0,5 mm in the amount from 1 to 12 wt%,

- dye pigment in the amount of up to 5 wt%.

Favourably, the Portland cement is Portland cement 52,5 in the amount from 20 to 30 wt%.

Favourably, the Portland cement is Portland cement 52,5 R-NA in the amount from 20 to 30 wt%.

Favourably, it contains a polymer in the amount from 0,01% to 5wt%.

Favourably, the polymer is polyvinyl alcohol.

Favourably, the grain of the foamed glass has a spherical shape.

The main advantage of the used mortar is significant shortening of the process of gluing the ceramic material to the wall. Once the adhesive has been applied to the tile and the tile has been fixed to the base, the overflow of the mortar coming out from under the tile is spread over and immediately forms the grout. Another advantage of the mortar according to the invention is less generated waste.

The adhesive and grouting mortar constitutes a mixture which combines the different advantages of the used components. Thanks to using Portland cement, high mechanical strength is obtained and replacing it with Portland cement 52,5 R-NA results in high dynamics of early strength increase as well as very high final strength and moderate hydration heat. Large amounts of hydrated lime were used in the mortar, which is characterized by high open porosity limited by the presence of capillary pores responsible for transport of moisture and water. Such a system of pores ensures very effective steam and carbon dioxide permeability as well as improves frostproof properties. Moreover, using hydrated lime makes it possible for moisture to migrate from the wall to the environment, while at the same time allowing salt to concentrate in a thin layer close to the surface of the wall, which is another advantage of the above mentioned mortar. Thanks to using quartz sand in the mortar, chemical and mechanical resistance is improved. The addition of cellulose ether in the mortar constitutes a retentive/thickening agent, while the trass meal reduces the risk of discolorations and efflorescence, while this additive also has a positive impact on the hydraulic properties reducing permeability and transport of water, plasticity and porosity. The foamed glass content, in turn, improves the thermal insulation properties of the adhesive and grouting mortar, improves the product's workability while the product itself is lighter than an identical mortar without this additive, moreover the likelihood of cracking is reduced and the mortar has better sound absorbing properties.

Thanks to adding calcium stearate the mortar has reduced caking properties. The mortar has the ability to be mixed easily, the ability of homogeneous mixing with other additives while being used and eliminates or drastically reduces the phenomenon of primary efflorescence as well as improves hydrophobic properties thanks to using polyvinyl alcohol.

Below are presented embodiments of the invention.

EMBODIMENTS

Einhodiinent 1. The following dry components of the mortar were poured into a mixer with the capacity of 1,4 m ³ in the following amounts:

Cement must fulfil the following requirements according to the standard PN-EN-19707:

Once the components had been poured inside, the mixer was turned on for ca. 30-35 minutes. When the mixing process was completed, the adhesive and grouting mortar was taken out of the container and packed into 25 kg bags. Next two bags of the adhesive and grouting mortar were taken to where the tiles were being fitted, the contents of both bags were poured into a container to which ca. 12,5 litres of make-up water were added and carefully mixed for about 10 minutes using an electric device. The make-up water was added at the water/joint ratio of 0.28.

The adhesive and grouting mortar prepared in this way is ready to be applied to surfaces with the aim to install ceramic materials. The overflow coming out while the tiles are being installed is used as grout, and its excess is removed after 5-10 minutes with a damp cloth, leaving the ceramic surface clean from any dirt. The adhesive and grouting mortar prepared in this way may be used to install ceramic tiles both inside and outside.

Emhodiment2. The following dry components of the mortar were poured into a mixer with the capacity of 1,4 m3 in the following amounts:

Cement must fulfil the following requirements according to the standard PN-EN-19707:

Once the components had been poured inside, the mixer was turned on for ca. 30-35 minutes. When the mixing process was completed, the adhesive and grouting mortar was taken out of the container and packed into 25 kg bags. Next two bags of the adhesive and grouting mortar were taken to where the tiles were being fitted, the contents of both bags were poured into a container to which ca. 12,5 litres of make-up water were added and carefully mixed for about 10 minutes using an electric device. The make-up water was added at the water/joint ratio of 0.28.

The adhesive and grouting mortar prepared in this way is ready to be applied to surfaces with the aim to install ceramic materials. The overflow coming out while the tiles are being installed is used as grout, and its excess is removed after 5-10 minutes with a damp cloth, leaving the ceramic surface clean from any dirt. The adhesive and grouting mortar prepared in this way may be used to install ceramic tiles both inside and outside.

The adhesive and grouting mortar prepared in this way is ready to be applied to surfaces with the aim to install ceramic materials.

Embodiment3. The following dry components of the mortar were poured into a mixer with the capacity of 1,4 m3 in the following amounts:

Cement must fulfil the following requirements according to the standard PN-EN-19707:

Once the components had been poured inside, the mixer was turned on for ca. 30-35 minutes. When the mixing process was completed, the adhesive and grouting mortar was taken out of the container and packed into 25 kg bags. Next two bags of the adhesive and grouting mortar were taken to where the tiles were being fitted, the contents of both bags were poured into a container to which ca. 12,5 litres of make-up water were added and carefully mixed for about 10 minutes using an electric device. The make-up water was added at the water/joint ratio of 0.28. The adhesive and grouting mortar prepared in this way is ready to be applied to surfaces with the aim to install ceramic materials. The overflow coming out while the tiles are being installed is used as grout, and its excess is removed after 5-10 minutes with a damp cloth, leaving the ceramic surface clean from any dirt. The adhesive and grouting mortar prepared in this way may be used to install ceramic tiles both inside and outside.

The adhesive and grouting mortar prepared in this way is ready to be applied to surfaces with the aim to install ceramic materials.

Embodiment 4. The following dry components of the mortar were poured into a mixer with the capacity of 1,4 m3 in the following amounts:

Cement must fulfil the following requirements according to the standard PN-EN-19707:

Once the components had been poured inside, the mixer was turned on for ca. 30-35 minutes. When the mixing process was completed, the adhesive and grouting mortar was taken out of the container and packed into 25 kg bags. Next two bags of the adhesive and grouting mortar were taken to where the tiles were being fitted, the contents of both bags were poured into a container to which ca. 12,5 litres of make-up water were added and carefully mixed for about 10 minutes using an electric device. The make-up water was added at the water/joint ratio of 0.28.

The adhesive and grouting mortar prepared in this way is ready to be applied to surfaces with the aim to install ceramic materials. The overflow coming out while the tiles are being installed is used as grout, and its excess is removed after 5-10 minutes with a damp cloth, leaving the ceramic surface clean from any dirt. The adhesive and grouting mortar prepared in this way may be used to install ceramic tiles both inside and outside.

The adhesive and grouting mortar prepared in this way is ready to be applied to surfaces with the aim to install ceramic materials.

Einhodiinent 5. The following dry components of the mortar were poured into a mixer with the capacity of 1,4 m3 in the following amounts:

Cement must fulfil the following requirements according to the standard PN-EN-19707:

Once the components had been poured inside, the mixer was turned on for ca. 30-35 minutes. When the mixing process was completed, the adhesive and grouting mortar was taken out of the container and packed into 25 kg bags. Next two bags of the adhesive and grouting mortar were taken to where the tiles were being fitted, the contents of both bags were poured into a container to which ca. 12,5 litres of make-up water were added and carefully mixed for about 10 minutes using an electric device. The make-up water was added at the water/joint ratio of 0.28.

The adhesive and grouting mortar prepared in this way is ready to be applied to surfaces with the aim to install ceramic materials. The overflow coming out while the tiles are being installed is used as grout, and its excess is removed after 5-10 minutes with a damp cloth, leaving the ceramic surface clean from any dirt. The adhesive and grouting mortar prepared in this way may be used to install ceramic tiles both inside and outside.

The adhesive and grouting mortar prepared in this way is ready to be applied to surfaces with the aim to install ceramic materials.

The invention can be used in construction in particular in finishing works for fitting both ceramic and stone tiles. Adhesives made based on the invention may be used for both installing ceramic materials and as grout fillings.

Embodiment 6. The following dry components of the mortar were poured into a mixer with the capacity of 1,4 m3 in the following amounts:

Cement must fulfil the following requirements according to the standard PN-EN-19707:

Once the components had been poured inside, the mixer was turned on for ca. 30-35 minutes. When the mixing process was completed, the adhesive and grouting mortar was taken out of the container and packed into 25 kg bags. Next two bags of the adhesive and grouting mortar were taken to where the tiles were being fitted, the contents of both bags were poured into a container to which ca. 12,5 litres of make-up water were added and carefully mixed for about 10 minutes using an electric device. The make-up water was added at the water/joint ratio of 0.28. The adhesive and grouting mortar prepared in this way is ready to be applied to surfaces with the aim to install ceramic materials. The overflow coming out while the tiles are being installed is used as grout, and its excess is removed after 5-10 minutes with a damp cloth, leaving the ceramic surface clean from any dirt. The adhesive and grouting mortar prepared in this way may be used to install ceramic tiles both inside and outside.

The adhesive and grouting mortar prepared in this way is ready to be applied to surfaces with the aim to install ceramic materials.

The invention can be used in construction in particular in finishing works for fitting both ceramic and stone tiles. Adhesives made based on the invention may be used for both installing ceramic materials and as grout fillings.

The invention can be used in construction in particular in finishing works for fitting both ceramic and stone tiles. Adhesives made based on the invention may be used for both installing ceramic materials and as grout fillings.