Failed Tile Decks Don’t Use Tiledek Waterproof Membrane

Tile decks are beautiful, but have a reputation as a trouble project and many contractors will shy away from them all together. There are countless stories out there about failed tiled deck projects where a home owner's beautiful new tile deck started leaking after only a short time. But you don't have to be afraid to surface your deck with tiles, even on a roof deck over living space. You only need to be sure to use a contractor that does it right, with the right products.

If you want to fulfil your dream of having a tile deck, talk to a few contractors to ensure you are getting one that knows the special considerations for tile deck projects....and if you don't hear them mention waterproofing...run away immediately! 

Read the full article....Failed Tile Decks Don’t Use Tiledek Waterproof Membrane

What You Need to Know to Avoid Leaky Tile Decks with Tiledek Membranes - Part 1

originally published September 3, 2012

Part 1 – Getting Familiar with Tiledek

Leaky tile decks are a source of frustration for many builders and homeowners throughout North America, particularly when the tile deck is above living space. However, the methods that have been used in the past without much success are no longer the only options. Duradek Ultra Tiledek was manufactured specifically to provide waterproofing peace of mind underneath exterior tile roof decks. It is the only roofing membrane specifically produced for waterproofing under outdoor tile AND that comes with a 10-year warranty that guarantees waterproof protection.

This month we will be publishing a 4-part series in a basic Q & A format every Wednesday to help you get acquainted with the specifics of Tiledek and waterproofing under exterior tile.

In part one, we will familiarize you with Tiledek and why it is the essential waterproofing component for outdoor tile projects.

What is Tiledek

Duradek Ultra Tiledek is a 60 mil thick, PVC roofing membrane similar to Duradek “Ultra”. It is designed to have outdoor porcelain tile or slate installed over top of it with a thinset mortar bond coat. Lightweight concrete or cementitious finishes can also be installed over it. From here on we will just refer to the overlay products as ‘tile’.

A fabric has been laminated to the topside of the roofing membrane to provide for a strong physical “grab” by the thinset mortar.  Tiledek comes in rolls 6 feet wide and 75 feet long.  Tiledek is only available as a “professionally installed waterproofing system” through the network of trained Duradek applicating contractors all over North America.

Is an outdoor tile application waterproof by itself?

Absolutely not!  It is absolutely certain that water will get under the tile.  That is precisely why there are so many problems with outdoor tile decks.  People THINK and are even misled to believe that a tile installation is waterproof and therefore they don’t pay too much attention to the proper waterproof treatment underneath. The failures are often waterproofing failures where leaks that have been happening undiscovered for years eventually cause rot requiring major renovation work.  Not only does the structure need replacement work, the tile application must also be torn up to get at it.

The water will most likely enter through cracked grout joints or on the perimeters.  If the tile cracks, water will enter.  If the deck is in a cold climate, the moisture freezes, expands and may cause tiles to erupt.

A failure in the tile installation doesn’t mean the waterproofing system has failed.  If the membrane is intact and performing its function of keeping the water out, replacing a cracked or erupted tile or a cracked grout joint is relatively easy and inexpensive.

What are Tiledek’s credentials?

Tiledek is a variation of Duradek Ultra, the first PVC walking roof deck material on the market.  Duradek Ultra has been installed for over 35 years and has proven itself in all climatic regions of North America.

Quality Auditing Institute Ltd.(QAI), an independent testing, inspection and certification agency, evaluated the Tiledek membrane (Evaluation Report T731-4), and based on this evaluation determined that Tiledek is considered compliant to the following criteria:

• ICC-ES:  Tiledek meets the requirements of ICC-ES AC39 "Acceptance Criteria for Walking Decks" and ICC-ES AC75 "Acceptance Criteria for Membrane Roof Covering Systems" as a roofing membrane when installed in accordance with the IBC 2009 or IRC 2009 and the manufacturers installation instructions.
• CAN/CGSB 37.54: Tiledek meets the requirements for conformance to the materials standard of CAN/CGSB-37.54-95 "Polyvinyl Chloride Roofing and Waterproofing Membrane" classified as a Type 3, Class A membrane.
• Class “A” Fire Rating: Tiledek is considered to have a Class “A” rating when tested to ULC-S107 "Methods of Fire Tests of Roof Coverings" and ASTM E-108 “Standard Test Methods for Fire Tests of Roof Coverings" (when installed on and covered by non-combustible building components).
• ASTM C627: Tiledek meets the requirements of the standard test method for evaluating ceramic floor installation using the Robinson-type floor tester. Test Report #UFT 2008-008, #UFT 2008-009, #UFT 2008-010.
  Test conducted by Terrazzo, Tile & Marble Association of Canada (TTMAC). 
• ANSI A118.10: Tiledek meets the requirements of the ANSI specification for load bearing, bonded, waterproof membranes for thin-set ceramic tile and dimension stone installations. Test Report #TCNA-428-10.
  Test conducted by the Tile Council of North America (TCNA).

Robinson Type Universal Floor Tester

Tiledek Techtalk #108 provides a summary of Tiledek testing and approvals in pdf format.

What is the warranty with Tiledek?

Tiledek is covered with the same waterproof warranty as Duradek Ultra – 10 years.  See the sample warranty on the Duradek website for the specific terms and conditions.

How is tile usually installed on decks and balconies?

There are two distinct methods of installing tile in waterproof applications:  thickset (using a 1-½ inch “dry mud bed”) and thinset (using a ¼ inch acrylic modified mortar).

Thickset Mortar

Thickset: Thickbed installations are based on the traditional method of packing a mortar bed over a surface before installing the tile. The tile is adhered to the mortar bed either while the mortar bed is green (just beginning to dry) or after the mortar bed has cured. The mortar bed may be reinforced with wire and either set over a cleavage membrane (that allows the mortar bed to "float" free of the substrate) or bonded to the substrate - hence the use of the terms "floating mortar bed" or "bonded mortar bed". For wall applications, metal lath is mechanically anchored to the substrate and the mortar locks into the metal lath as it cures. The terms thick-bed installation, mortar bed installation, and thickset installation are synonymous.

The thickset method is more likely to be used where the tile is thick and irregular in order to achieve a flat walking surface.

Thinset Mortar

Thinset: Thinset mortar is a blend of cement, very finely graded sand, and a water retention compound that allows the cement to properly hydrate. Tile set by the thinset method is adhered to the substrate with a thin layer of "thinset" mortar. This type of cement is designed to adhere well in a thin layer - typically not greater than 3/16th thick. For example, a 3/8" notch trowel will produce a 3/16th inch thick coating after the tiles are pressed in to the cement. While very minor adjustments in height can be made, this method is not appropriate for adjusting the level or flatness of a surface - rather the tile will follow the plane of the substrate. Only “Gauged” tiles (with similar thickness) should be used in thinset mortar applications.

Medium-set: Medium-set mortars can be used to adjust for slightly larger variations in the substrate than can be accommodated with thinset mortar. They are also used with large, heavy, thick or “ungauged” (varying thickness) tiles, where a thicker setting bed and a coarser aggregate may be required to achieve a flat installation and to support the weight of the tile while the cement is curing.

Summary

Now that you are more familiar with Tiledek and the types of outdoor tile installation methods, be sure to check back next week for part 2 in this series –“ What You Need to Know to Avoid Leaky Tile Decks with Tiledek Waterproof Membrane: Part 2 – The Alternatives”.

In the meantime, you may like more detailed information from the trained and authorized Tiledek installer in your area.

 

Deck Expert Bill Leys to Educate on Tile Decks at JLC Live Northwest

Deck Expert, Bill Leys, will be at JLC Live Northwest on Wednesday, December 4, 2013 conducting a conference session that focuses in on tile deck best practices, and you can get a $30 discount (code SPKG) if you register before November 7th.

As a licensed contractor in California and owner of DeckExpert.com, Bill Leys specializes in the installation of deck coatings for decks over living space and is very familiar with the Duradek family of deck waterproofing solutions. An authoritative voice in the deck building industry, Bill brings a not-to-miss highlight of JLC Live Northwest with his education session. Since waterproof decks and/or tile-covered waterproof decks rate high on the list of components claimed to have construction defects, this is an incredibly valuable 2 ½ hours for any construction professional who takes on decking projects.

Tildek, as part of the outdoor tile assembly is one of
the best ways to ensure waterproof success in exterior tile projects.

Bill presents “Construction and Waterproofing Methods for Walking Decks and Tile Covered Decks” which takes place on Wednesday, December 4th, 2013 from 9:30 a.m. to 12:00 p.m. The session covers best construction practices and will be divided into two parts.

The first half discusses pedestrian deck systems and best building practices to construct a well built and long lasting deck assembly.

The second half instructs on roof decks and how to properly build and waterproof them for a systems to last 30+ years.

Learning objectives include:

• Best practices when installing new waterproof systems for tile.
• Best practices in building and framing a deck that will receive tile, which materials are available for waterproofing tile decks.
• How to properly sequence the waterproofing of the deck with the construction of the building.
• Tile Council of North America standards and methods for tile decks. (Durdek Ultra Tiledek has been tested to meet TCNA ANSI specification for load bearing, bonded, waterproof membranes for thin-set ceramic tile and dimension stone installations.)
• Reduce your risk of exposure to liability.

JLC Live Northwest 2013 takes place at the Oregon Convention Center in Portland, OR with conferences from December 4 – 6 and Exhibit Hall from December 5 – 6.

Register at JLCLIVE.com with promo code SPKG by November 7th, 2013 to receive a $30 conference discount on a 3-day conference pass. Your conference pass includes:

• Free access to the live demos and clinics
• Exhibit Hall
• Welcome Party

JLC Live Northwest is the premier regional industry event for residential construction in the Pacific Northwest and offers real world construction education with a conference program that highlights fundamental business and technical skills.

If you are in the Pacific Northwest and are interested in waterproofing solutions for decking, you can also talk to Matt at Duradek Northwest who is a waterproofing expert in his own right!

Duradek Invites You To Coverings 2013 in Atlanta

Coverings, the ultimate tile and stone experience, is only a few weeks away and Duradek would like to invite you to attend with this offer of FREE REGISTRATION. Taking place April 29th to May 2nd at the Georgia World Congress Center in Atlanta, GA, this is your opportunity to discover what the experts are saying about the latest in surface finishing.

Coverings Presents:

• 4 days of exhibits with over 900 exhibitors offering the best in the tile and stone surface covering products.
• More than 70 FREE specialized training and education sessions.
• Feature speakers addressing the latest in design, marketing and labor trends.
• Installation demonstrations and design showcase.
• Special programs like the CID Design Awards and Project Green.
• ....and more!

Be sure to stop by the Duradek booth #7665 to learn about Duradek Ultra Tiledek, the waterproofing membrane for under exterior tile and the time-proven Duradek Ultra walkable roofing membrane that has protected over a million square feet of decks all across North America.

Duradek Expert Shares Exterior Tile Deck Advice with the Construction Specifier

Exterior tile decks can be a tricky subject for even experienced contractors, but for anyone who desires insights on the subject of exterior tile decks, there is a great resource included in the February 2013 issue of the Construction Specifier magazine.

‘Avoiding Leaky Exterior Tile Decks’ written by Duradek president, John Ogilvie, is a detailed article that discusses the waterproofing details that can make the difference between a successful and a failed tile deck project.  Having spent nearly 40 years in the deck waterproofing industry mastering the use of PVC membranes for roof deck waterproofing, John knows a thing or two about waterproofing details and the critical elements that are required to protect a home from the constant influence of moisture or water penetration.



A beutiful tile deck waterproofed with Tiledek,
installed by Duradek of Utah

In fact, it was John’s decades of experience with deck and flat roof waterproofing combined with the exterior tile industry’s need for a better waterproofing solution that inspired the creation of Duradek Ultra Tiledek, the under-tile waterproofing membrane. Particularly when used on decks built over living space, Tiledek provides significant peace of mind as it is a true roofing membrane, designed specifically for use with outdoor tile.

Here are some of the vital components to exterior tile decking projects that Duradek president, John Ogilvie discusses in this article:

Installing Tile on Decks and Balconies

• Thick-set Method
• Thin-set Method

Causes for Tile Failure

• Building the Deck
• Waterproofing
• Thin –set Bonding Adhesive
• Choosing the Tile or Stone
• Tile Installation Techniques
• Details
• Waterproofing or Roofing
• Railings
• Maintenance

Preventing Failures

• Sloping the Surface

Waterproofing Options for Under Exterior Tile

Critical Installation Details

• Outside Perimeters
• Drains
• Rail Attachments
• Inside Perimeter
• Surface Preparation
• Installation Qualifications

View the .pdf of “Avoiding Leaky Exterior Tile Decks” or view online at the Construction Specifier.

 

If you’ve had issues with tile decks in the past, or are even considering building an exterior tile deck, this article is well worth taking the time to read to become aware of the details that can save you hundreds of dollars and plenty of time by avoiding a leaky tile deck.



Exterior Tile Waterproofing for Roof Decks with Tiledek.

Newly Renovated Hoover Pavilion Pyramid Waterproofed by Tiledek

One of the first projects of Stanford University’s $5 billion Medical Center Renewal Project and Expansion that is underway was the Hoover Pavilion, and Duradek Ultra Tiledek was very proud to be a part of such a significant undertaking.

Hoover Pavilion Open House
– Thursday, December 6th, 2012

Stanford University is inviting the public to an open house to view the newly renovated Hoover Pavilion to honor this historic structure’s place in the legacy of clinical and community care.
On Thursday, December 6th a welcome reception launches the event at 10:00 a.m., followed by a short ceremony at 10:30 a.m. and tours of the newly renovated facility between 11:00 a.m. and 12:00 p.m.

Hoover Pavilion Pyramidal Roof Protected by Tiledek

Originally built in 1930 as the Palo Alto Hospital, it was renamed the Hoover Pavilion in 1965 after Stanford University School of Medicine relocated to Palo Alto from  San Francisco. The restoration and reuse of the historic 1931 facade and building allows the project to honor this landmark structure’s place in the legacy of caring at Stanford. While the Hoover Pavilion site is modernized, it still maintains its historic image.



The Hoover Pavilion when it was known as the Palo Alto Hospital

The most distinguishing feature of the Pavilion is the Pyramidal Hip Roof, and this is where Duradek Ultra Tiledek has been utilized to protect the structure from the elements. Tiledek was the perfect choice for waterproof protection for this part of the roof, particularly since the design includes thin set tiles on its sloped surface. 

Lawson Roofing, who is responsible for the pyramidal hip roof as well as all of the other roofing and waterproofing aspects of the Hoover Pavilion and the new parking facility, knew they needed a product that would perform flawlessly for this very unique project. Since the pyramidal roof is sloped at such a steep angle, they had to be sure that the tiles would be able to be securely adhered to the waterproofing membrane. With the textured surface of Tiledek designed specifically to best adhere thin set tiles and its 10-year waterproofing warranty; it was the perfect product choice to protect such a historic and relevant structure.

Pyramidal Roof at the Hoover Pavilion Reconstruction

Since Duradek products are only installed by trained and authorized dealers, the crew at Lawson Roofing had to be specially trained in the details of installing Duradek Ultra Tiledek. Technical Manager, Len Viegener made the trip to San Francisco to conduct the training himself for this special, one-time only installation for the Hoover Pavilion. 

For any Duradek inquiries in the San Francisco area, contact authorized Duradek dealer Paul from Golden Gate Enterprises.  Paul is a veritable deck waterproofing specialist! He has posted over a 100 YouTube videos regarding deck waterproofing that include some very revealing information about the importance of details and the ugly truth of what happens when deck waterproofing is not performing properly.

If you are interested in learning more about how Duradek Ultra Tiledek can be the solution for your exterior tile roof deck, contact one of our authorized Duradek Dealers in your area for some detailed information specific to your project.

What You Need to Know to Avoid Leaky Tile Decks with Tiledek Waterproof Membrane: Part 4 – Stacking the Deck

In this four-part series of detailed questions about Duradek Ultra Tiledek membranes we first familiarized you with Tiledek, discussed the alternative methods of waterproofing under exterior tile and why Tiledek is the stand-out option for doing it right the first time and guaranteeing that your deck waterproofing performs as intended.

In this fourth and final part of our Tiledek series of articles we will discuss how to first prepare your deck surface to achieve waterproofing success.

How do you build a deck to make it is ready for tile?

A major cause of failure of tile over decks and balconies is that the structure to which it is applied allows too much deflection.  Tile has little tolerance for deflection.  Cracking grout lines or tile is the result of deflection. 

Deflection (the spring or give of the deck surface) is a product of the joist spacing and thickness of the flooring materials.  The Terrazzo, Tile and Marble Association of Canada (TTMAC) specification for flooring under tile or slate is as follows:
¾ inch plywood fastened with 2” #10 Exterior wood screws @6” oc @ perimeter and 8” oc @ joists covered with ½ inch cement board secured with thinset and fasteners. (The deck must have slope built in – suggested slope ¼” per foot)

The use of a cement board overlay is required/recommended by tile associations and manufacturers.  Cement board, unlike plywood, is not affected by varying levels of moisture.

We strongly recommend that decks be built to this specification.  For the money that is being invested in the whole system, it would seem unwise to scrimp on the subsurface.  In case of a failure (cracking), the first thing anyone will look at (and blame it on) is whether the floor was strong enough and provided the necessary deflection resistance.

Concrete decks and balconies are suitable for tile application but still require proper waterproofing or roofing protection.

We recommend you follow the local best practice guidelines as laid out by the Tile Contractors Association of TTMAC or the building code. There may be regional differences in the suggested use of cement board or a second layer of plywood. As with all the details involved with a tile deck over a wood structure, you should follow the tile and thinset mortar manufacturer’s specifications.

Can tile be applied over an existing vinyl deck?

Most existing deck surfaces (PVC membrane or liquid applied finishes) are applied to 5/8 inch or ¾ inch plywood and therefore are not suitable for a tile overlay without some stiffening to reduce the deflection.  The vinyl could be removed (possibly leaving the existing vinyl up the wall behind the siding and building paper), the floor stiffened with the appropriate thickness of cement board and the Tiledek installed over top (special details will be published for this).

There is another system that can be used to stiffen the existing structure.  Schluter’s ditra mat can be installed over top of Tiledek (with thinset) and then the tile can be installed over top of Ditra.  The Ditra mat stiffens the floor system to an appropriate level to provide for residential use of tile.  We have tested this system with the Robinson Floor test and achieved a “residential” result. 

Should you protect Tiledek until the tile is applied?

Like all products installed on a construction site, Tiledek is susceptible to damage from other trades, scaffolding, paint, stucco, materials or tools being dropped from above or other abuse.  Although Tiledek is very tough (as we know from Duradek) and can take a lot of abuse, it is always wise to protect it especially in heavy traffic areas or areas which are most likely to be damaged.  Covering it with a protection board (plywood, recovery board etc) will save time and effort cleaning the Tiledek to prepare it for accepting the tile overlay.  A layer of polyethylene under the panels will protect the membrane from liquids (paints etc). Another method of protection would be to trowel apply directly to the Tiledek a thin coating of the same thinset material that will be used to apply the tile or stone overlay. 

How do you clean Tiledek if necessary?

If Tiledek has been left exposed to traffic and construction debris and needs to be cleaned, it can be cleaned easily and effectively.  Pressure washing with a light (1500 psi) spray with the nozzle no closer than 6 inches from the surface will work well.  The surface can also be washed and lightly scrubbed with a bristle broom and hosed off.

Does the surface need to be sloped?

Yes!  Sound roofing/waterproofing practice needs to be employed even when tile is applied over top.  We operate on the expectation of water getting through the tile installation.  Our membrane will be applied to a surface sloped towards drains, scuppers or an outside edge which allows the water to escape. 

Moisture will still run downhill, even under tile applications.  This can happen without negatively affecting the bond of the thinset mortar to the tile or the membrane.

We recommend the seams of the Tiledek run parallel to the slope to avoid any water puddling up behind the bump.

Can a flat waterproof surface be re-sloped with a thickset application technique?

While it is possible to provide a slope with the thickset mortar, there are other problems to consider.  If the waterproof membrane is flat or allows water to puddle on it, providing a sloped mortar bed will NOT remove all the water from the deck.  Although most of the moisture will drain off the top surface, water WILL enter under the tile through cracks in the grout joints, cracks in the tile or on perimeters.  The water that enters will follow the slope of the waterproofing membrane.  If it puddles before the thickset mortar goes on, it will still puddle after the tile job is completed.  The water will then just sit in a puddle and stagnate, potentially causing mould and an unpleasant odor to occur.
If you want to take a belly or depression out of the deck surface, it must be done prior to the Tiledek being installed. Since water will not penetrate Tiledek, if the depression has been eliminated any water reaching it will be shed away.

Water testing before the Overlay is Applied

We recommend a water test be done after the Tiledek is installed and prior to the overlay being applied.

Conclusion

If you have read all four parts of this series of articles on Tiledek and waterproofing methods for exterior tile projects, you are well equipped to ask all of the right questions to all parties involved in the construction of a reliable and long-lasting outdoor tile deck.

At Duradek we believe that your deck should be a source of pleasure, not stress, and we encourage all home owners and builders to ensure they do it right the first time….do it with Duradek Ultra Tiledek.

What You Need to Know to Avoid Leaky Tile Decks with Tiledek Waterproof Membrane: Part 3- Installation

In part one of this four-part series of detailed questions about Duradek Ultra Tiledek membranes we first familiarized you with Tiledek and the necessity of having a reliable waterproof system under your outdoor tile decks and the typical methods of installing outdoor tile.

In part two, we discussed the alternative methods of waterproofing under exterior tile, and why Tiledek is the superior choice.

In this third part of this series we will expand on why Tiledek is the stand-out option for doing it right the first time and guaranteeing that your deck waterproofing performs as intended.

How is Tiledek installed?

Tiledek is installed using almost identical techniques to the installation of Duradek. We use the same adhesives, heat welded seams, and waterproofing details. There are a few finish details that differ due to the tile that will be installed after we are done. Here are the areas that require different techniques:

Tile Deck with Custom Flashing Details

Outside perimeters: As with regular Duradek, there are many ways to finish the outside perimeter of a tile deck. As water proofers, we need to establish what “look” the owner wants to be able to advise them properly. You should consult with both the builder and the tile setter to discuss the perimeter finish details. Depending upon their desired finish, we can alter our detailing. This is an area where we can offer our customers excellent service and help them make good waterproofing decisions while taking all the future steps they will go through into consideration. Our attention to these details contributes to the overall success of the job.

Drains: Should drains be necessary, we cannot use our regular WDD1 system. We recommend a special cast drain with a square top to make it easier and more attractive for the tile applicator to finish to.

Rail attachments: We strongly recommend attaching rails to the fascia instead of the surface of the deck. DO NOT INSTALL RAILS OVER TOP OF TILE AS IT WILL CAUSE THE OVERLAY TO CRACK. We have special details for surface mounted rails if there is no other alternative.

Proper installation required running the membrane
up the wall and "cut-in" to the brick.

Inside perimeter: If the owner wants the tile to return up the wall as part of their finished look, appropriate flashings are needed. If not, then consideration must be given to the visibility of the part of the membrane that returns up the wall and hiding the gap that must be left on the inside of the tile application.

Surface preparation: Apart from a thorough inspection for a properly fastened substrate, there is little prep work necessary. A light sanding of the joints of the cement board or a scraping of the entire surface to take care of any bumps will suffice. No filling is required.

Who installs Tiledek?

Tiledek can only be installed by a qualified Duradek applicator who has gone through our training program and who works for an authorized Duradek applicating contractor. That is how we can give our customers superior protection in making sure it is done right.

Do we recommend tile installations in cold climates?

We do not profess to be tile experts. Manufacturers of the tile and the installation accessories must answer this question. We are waterproofing professionals. We can protect the structure from water damage no matter how hot or cold or wet the climate is. And we can provide a membrane to which thinset mortars will tenaciously adhere. We cannot (and do not) guarantee tiles will not erupt as a result of freezing temperatures but we can (and do) guarantee the water that gets under the tile will not get into the building.

There are currently countless decks and balconies in cold climates being overlaid with tile. People like the look and are going to continue to use it regardless of if it is a good idea. Our part is to make sure they don’t suffer water damage.

Is Tiledek an Anti Fracture Membrane?

Example of Tiledek Assembly Build Up

Tiledek will add a very small amount of fracture resistance to the system but should not be purchased as an anti-fracture membrane. Because it is glued to the subsurface, movement beneath the Tiledek membrane may transfer through into the tile.

Will an anti-fracture membrane eliminate the need for a control joint?

It is a frequent misconception that anti-fracture membranes allow you to eliminate expansion joints - they do not. There always must be soft joints in the tile work to allow for expansion and contraction. Guidelines for expansion joint placement are given in the Tile Council of North America Handbook. The exact placement of expansion joints is a function of many items including exposure to sunlight and the range of high to low temperature, moisture, aging of the concrete (where relevant), structural movement, expected loading, and other design criteria. It is a common recommendation that there be expansion joints every 8 - 10 feet in any direction. The manufacturer's recommendations should also be consulted and followed.

On ¾ inch plywood covered with Tiledek plus a layer of Schluter’s Ditra Mat, we achieved a residential rating.

Summary

Now that you know some of the installation details to consider, check back next week for the final article in our 4-part series, “What You Need to Know to Avoid Leaky Tile Decks with Tiledek Waterproof Membrane: Part 4 – Stacking the Deck”.

What You Need to Know to Avoid Leaky Tile Decks with Tiledek Waterproof Membrane: Part 1

Part 1 – Getting Familiar with Tiledek

Leaky tile decks are a source of frustration for many builders and homeowners throughout North America, particularly when the tile deck is above living space. However, the methods that have been used in the past without much success are no longer the only options. Duradek Ultra Tiledek was manufactured specifically to provide waterproofing peace of mind underneath exterior tile roof decks. It is the only roofing membrane specifically produced for waterproofing under outdoor tile AND that comes with a 10-year warranty that guarantees waterproof protection.

This month we will be publishing a 4-part series in a basic Q & A format every Monday to help you get acquainted with the specifics of Tiledek and waterproofing under exterior tile.

In part one, we will familiarize you with Tiledek and why it is the essential waterproofing component for outdoor tile projects.

What is Tiledek

Duradek Ultra Tiledek is a 60 mil thick, PVC roofing membrane similar to Duradek “Ultra”. It is designed to have outdoor porcelain tile or slate installed over top of it with a thinset mortar bond coat. Lightweight concrete or cementitious finishes can also be installed over it. From here on we will just refer to the overlay products as ‘tile’.

A fabric has been laminated to the topside of the roofing membrane to provide for a strong physical “grab” by the thinset mortar.  Tiledek comes in rolls 6 feet wide and 75 feet long.  Tiledek is only available as a “professionally installed waterproofing system” through the network of trained Duradek applicating contractors all over North America.

Is an outdoor tile application waterproof by itself?

Absolutely not!  It is absolutely certain that water will get under the tile.  That is precisely why there are so many problems with outdoor tile decks.  People THINK and are even misled to believe that a tile installation is waterproof and therefore they don’t pay too much attention to the proper waterproof treatment underneath. The failures are often waterproofing failures where leaks that have been happening undiscovered for years eventually cause rot requiring major renovation work.  Not only does the structure need replacement work, the tile application must also be torn up to get at it.

The water will most likely enter through cracked grout joints or on the perimeters.  If the tile cracks, water will enter.  If the deck is in a cold climate, the moisture freezes, expands and may cause tiles to erupt.

A failure in the tile installation doesn’t mean the waterproofing system has failed.  If the membrane is intact and performing its function of keeping the water out, replacing a cracked or erupted tile or a cracked grout joint is relatively easy and inexpensive.

What are Tiledek’s credentials?

Tiledek is a variation of Duradek Ultra, the first PVC walking roof deck material on the market.  Duradek Ultra has been installed for over 35 years and has proven itself in all climatic regions of North America.

Quality Auditing Institute Ltd.(QAI), an independent testing, inspection and certification agency, evaluated the Tiledek membrane (Evaluation Report T731-4), and based on this evaluation determined that Tiledek is considered compliant to the following criteria:

• ICC-ES:  Tiledek meets the requirements of ICC-ES AC39 "Acceptance Criteria for Walking Decks" and ICC-ES AC75 "Acceptance Criteria for Membrane Roof Covering Systems" as a roofing membrane when installed in accordance with the IBC 2009 or IRC 2009 and the manufacturers installation instructions.
• CAN/CGSB 37.54: Tiledek meets the requirements for conformance to the materials standard of CAN/CGSB-37.54-95 "Polyvinyl Chloride Roofing and Waterproofing Membrane" classified as a Type 3, Class A membrane.
• Class “A” Fire Rating: Tiledek is considered to have a Class “A” rating when tested to ULC-S107 "Methods of Fire Tests of Roof Coverings" and ASTM E-108 “Standard Test Methods for Fire Tests of Roof Coverings" (when installed on and covered by non-combustible building components).
• ASTM C627: Tiledek meets the requirements of the standard test method for evaluating ceramic floor installation using the Robinson-type floor tester. Test Report #UFT 2008-008, #UFT 2008-009, #UFT 2008-010.
  Test conducted by Terrazzo, Tile & Marble Association of Canada (TTMAC). 
• ANSI A118.10: Tiledek meets the requirements of the ANSI specification for load bearing, bonded, waterproof membranes for thin-set ceramic tile and dimension stone installations. Test Report #TCNA-428-10.
  Test conducted by the Tile Council of North America (TCNA).

Robinson Type Universal Floor Tester

Tiledek Techtalk #108 provides a summary of Tiledek testing and approvals in pdf format.

What is the warranty with Tiledek?

Tiledek is covered with the same waterproof warranty as Duradek Ultra – 10 years.  See the sample warranty on the Duradek website for the specific terms and conditions.

How is tile usually installed on decks and balconies?

There are two distinct methods of installing tile in waterproof applications:  thickset (using a 1-½ inch “dry mud bed”) and thinset (using a ¼ inch acrylic modified mortar).

Thickset Mortar

Thickset: Thickbed installations are based on the traditional method of packing a mortar bed over a surface before installing the tile. The tile is adhered to the mortar bed either while the mortar bed is green (just beginning to dry) or after the mortar bed has cured. The mortar bed may be reinforced with wire and either set over a cleavage membrane (that allows the mortar bed to "float" free of the substrate) or bonded to the substrate - hence the use of the terms "floating mortar bed" or "bonded mortar bed". For wall applications, metal lath is mechanically anchored to the substrate and the mortar locks into the metal lath as it cures. The terms thick-bed installation, mortar bed installation, and thickset installation are synonymous.

The thickset method is more likely to be used where the tile is thick and irregular in order to achieve a flat walking surface.

Thinset Mortar

Thinset: Thinset mortar is a blend of cement, very finely graded sand, and a water retention compound that allows the cement to properly hydrate. Tile set by the thinset method is adhered to the substrate with a thin layer of "thinset" mortar. This type of cement is designed to adhere well in a thin layer - typically not greater than 3/16th thick. For example, a 3/8" notch trowel will produce a 3/16th inch thick coating after the tiles are pressed in to the cement. While very minor adjustments in height can be made, this method is not appropriate for adjusting the level or flatness of a surface - rather the tile will follow the plane of the substrate. Only “Gauged” tiles (with similar thickness) should be used in thinset mortar applications.

Medium-set: Medium-set mortars can be used to adjust for slightly larger variations in the substrate than can be accommodated with thinset mortar. They are also used with large, heavy, thick or “ungauged” (varying thickness) tiles, where a thicker setting bed and a coarser aggregate may be required to achieve a flat installation and to support the weight of the tile while the cement is curing.

Summary

Now that you are more familiar with Tiledek and the types of outdoor tile installation methods, be sure to check back next week for part 2 in this series –“ What You Need to Know to Avoid Leaky Tile Decks with Tiledek Waterproof Membrane: Part 2 – The Alternatives”.

In the meantime, you may like more detailed information from the trained and authorized Tiledek installer in your area.

 

Tile Decks: Robinson Testing for Performance

Tiledek Under-Tile Membrane

Ceramic tile floor assembly testing is a valuable way of determining and measuring a (flooring) system’s performance prior to installation. While outdoor tile decks, particularly when over living space, have no specific testing criteria, testing the flooring assembly provides the peace of mind that the system is going to perform as intended in its real-world application. Duradek Ultra Tiledek under-tile membrane has been thoroughly tested in a ceramic tile floor assembly and can confidently offer a 10-year waterproofing guarantee.

Tile Floor Testing History

Robinson Floor Tester

During the development of the thin-set method for installing ceramic tile back in 1958, Donald Robinson, the head of engineering research at the Tile Council Research Center, designed a testing machine to evaluate the performance of such a method on floors. Adopted as ASTM test method C-627 in 1970, the apparatus is commonly known as “The Robinson Floor Tester” and the ASTM C-627 is still used today as the benchmark for performance of all types of flooring products.

Some technical consultants agree that the only problem with the Robinson Floor Tester is that it doesn’t necessarily give you the full picture since it is only a 4’ x 4’ pad the assembly is placed on, which may hinder the system from mimicking an entire floor installation.

Recognizing this, the Terrazzo, Tile and Marble Association of Canada (TTMAC) developed a more modern and advanced testing machine that can perform the ASTM C-627 for both conventional size test formats (4’ x 4’) or more real-life longer spans (up to 20’). Developed about nine years ago, the Universal Floor Tester tests assemblies following ASTM C-627 criterion and designates five levels of performance:

• Residential (three cycles)
• Light Commercial (six cycles)
• Moderate Commercial (ten cycles)
• Heavy Commercial (twelve cycles)
• Extra-Heavy Duty (fourteen cycles)

Robinson-Type Universal Floor Tester

How Tile Floor Testing is Performed

The test requires a carriage with three wheels that rotate over the same path consistently with specific weights and a specific type of wheel designated for each cycle performed. Testing criteria is determined by being aware of what type of conditions under which the flooring will be used and then simulating those conditions.

The test assembly is placed under the carriage of the machine, and the first set of wheels, which are made of soft rubber, are installed along with steel plates weighing a total of 300 lbs. The cycle takes approximately one hour to complete 900 revolutions, and the load is continually increased by 150 lbs. for each cycle up to 900 lbs.

After each cycle the technician inspects the assembly to see if any cracks, chips, loose tiles, etc. exist. If the assembly (the whole assembly system is observed for each cycle) is unaffected after four cycles, the wheels are changed to hard rubber and the process is repeated until there is evidence of failure or the eighth cycle is complete.

The final last two levels of performance require the use of steel wheels and to once again run the test through the increasing weights for each cycle. Once the test is completed or a failure is observed, the test is stopped and observations, readings and pictures are taken. The final test classification is then determined and the testing technician provides a written report.

This test is extremely useful because it allows a simulated representation of what will occur at the installation site. In addition, you are able test many types of material to demonstrate whether or not certain materials are able to work together.

Does Tiledek pass the Robinson Floor test?

Tiledek was tested to ASTM C627 (the Robinson Floor Test) on TTMAC’s Universal Floor Tester to see how suitable our system was for application under tile.  Tile has very little tolerance for any deflection or movement of the surface to which it is installed.  Too much deflection or if the membrane beneath is too soft may cause cracking of the grout lines or the tile.

Tested over ¾ inch plywood and ½ inch cement board, Porcelain tile on Tiledek achieved a “Heavy” rating with no cracking of tile or grout lines after 9000 revolutions with 600 pounds on steel wheels (on the twelfth cycle).  This is much more than would ever be necessary for residential traffic on a roof deck.

On the same subsurface assembly, Tiledek achieved a “residential” rating on slate.  There were no signs of cracking on the slate or the grout lines.  The failure was in the slate itself which showed signs of the surface deteriorating where the steel wheels made contact.

Builders and contractors may disagree on many things but there is one thing that most would agree on:  Exterior tile projects are often ‘problem’ jobs. Duradek Ultra Tiledek hopes to change that perspective with the performance value of Tiledek under-tile roof membranes.

To learn more about Duradek Ultra Tiledek, check our blog each Monday in September as we publish a 4-part series detailing the specifics of Tiledek and tile installation methods.

Beautiful Tile Deck Waterproofed with Tiledek Membrane

Outdoor Tile - A Step-By-Step Process For Pedestrian Tile Surfaces

If you are considering installing outdoor tile at your home or business, there are many factors to consider in ensuring it is the right material for your needs. That being said, the methods employed today to install exterior tile are far superior to those of the past and exterior tile is much more accessible to the average homeowner.

Proper application of outdoor tile surfaces requires not just the skills of the tile layer. One of the most critical phases of an outdoor tile installation is the waterproofing phase. A vinyl membrane is one of the most effective ways to provide exterior waterproofing as part of a tile assembly, and Duradek Ultra Tiledek is gaining a reputation as one of the best methods of fulfilling this need. Not only does it provide waterproof protection for the substrate of the tile assembly, it is also a roofing-approved membrane and will guarantee waterproof protection over habitable space allowing tiles to be used with confidence on roof top decks. In addition, its structure provides a durable and flexible surface that the tiles stay adhered to over years of freeze and thaw cycles.

Matt McClure of Duradek of Utah / Dek Max is a bona fide expert in waterproofing balconies, patios and roof top decks. As a specially trained Duradek Distributor, Matt is a well-respected voice of authority in the decking industry and is often turned to for advice on best practices in waterproofing.

While you can see a summary of the entire process and many stages of installing outdoor tile in our blog article "Exterior Tile Decks - A Big Job One Step at a Time", below you will find a series of video clips covering the waterproofing stage of the tile installation assembly.

Stage 1 - Laying Out the Vinyl






Stage 2 - Applying Latex Adhesive to Cement Board






Stage 3 - Applying Contact Cement to the Edge of the Deck






Stage 4 - First Weld of Tiledek






Stage 5 - Second Weld of Tiledek






Stage 6 - Third and Final Cap Weld of Tiledek





The popular decking resource, Ideas for Deck Designs approached Matt to share his expertise and you can  benefit from his experience by reading his interview and reviewing a step-by-step sequence of a new tile deck installation on their website.

If you would like to look into the benefits of Tiledek for your particular project, contact a Duradek dealer in your area for a free, no-obligation estimate and get one step closer to making your dreams of a tile deck a reality.