Studies On The High Performance Cement-based Ceramic Tile Binders

"Large scale and ultra-thin building ceramic tiles" compared with the traditional wall and floor ceramic tiles, have the advantages of energy saving, material saving,environmental protection, high construction efficiency, good decorative effect, and so on. But the disadvantages for the “large scale and ultra-thin building ceramic tiles are:the weight of single ceramic tile is so large that it is easy to shift during the paving; the internal stress between the binder and the ceramic tile due to the variety of deformation is large, which easily leads to the ceramic tiles warping, fracturing and spalling; the production of ceramic tiles added a large number of artistic elements(such as texture,color, printing etc.), the decorative effect of ceramic tiles are prone to be stained because of the mortar efflorescence.To better show the technology and performance advantages of large scale and ultra-thin building ceramic tile, this study specially developed a ceramic tile binders for them with cement as cementing material, quartz sand as aggregate and supplemented functional materials. By using the orthogonal experiments, the effect of binder’s composition on its mechanical properties and volume stability was analyzed; single factor and orthogonal test was used to analyze the capable of efflorescence resistance of the binder. The main research conclusions are concluded as follows:(1) Through orthogonal test, the bonding strength, compressive/flexural strength and shrinkage rate of cement-based binder were tested, and analyzed the influence of redispersible polymer powder, wood fiber, expansive agent and binder/sand ratio on them. On the basis of meeting the bond strength, the redispersible polymer powder by film-forming reinforcement effect, can significantly improve the toughness of cement-based binder(compressive/flexural strength to reduce); it is the most significanteffect that the binder/sand ratio to shrinkage rate of cement-based ceramic binder and the effect of wood fiber and expansive agent is less. The optimum composition of binder is 1.5% redispersible polymer powder, 0.3% wood fiber, 3.0% the expansive agent, 0.3% cellulose ether, 0.1% the high efficiency water reducing agent, 36.0%cement, 58.8% quartz sand by comprehensive analysis.(2) The line expansion rate of binder increased with the increase of temperature.The temperature line expansion coefficient of ceramic tile binder obtained from this research is according to that of normal cement concrete, basically.(3)Ca(OH)2 precipitates and carbon deposition are the important form of efflorescence; ceramic tile binders contained different mineral admixtures, i.e., fly ash,slag and metakaolin, can effectively reduce the efflorescence, especially the incorporation of 20% fly ash reduce the efflorescence most remarkably.(4)The results of orthogonal test showed that, when adding compound inhibitor in the binder combined with 1.5% hydrophobic polymer powder, 8% aluminate cement,20% fly ash, ceramic tile adhesives have excellent efflorescence resistance.The developed ceramic tile binder has appropriate mechanical properties, the excellent volume stability and efflorescence resistance ability, and can meet the large scale and ultra-thin building ceramic tile’s requirements.