Products : Setting : Rapid Setting Mortars : MegaLite® Rapid Setting Crack Prevention Mortar

MegaLite® Rapid Setting Crack Prevention Mortar

A premium one part formula with the high, fast bond strengths and flexibility to withstand horizontal movement to isolate substrate cracks up to 1/8" (3 mm). For time-critical commercial and residential installations under the most demanding requirements, capable of thin-set or medium bed application up to 3/4" (19 mm) thick on horizontal surfaces after beat in. Non-slump, medium-bed features provide the ultimate support for large format tile and stone. No need for two part additives to meet high bond and flexibility or compressive strength requirements. The rapid setting formula allows grouting in less than 3 hours, traffic in 4 hours. A 30 lb (13.6 kg) bag covers the same area as a 50 lb (22.68 kg) bag of traditional mortar. Use for interior or exterior floors, countertops and walls. Formulated with recycled material contributes to LEED® certification. Exceeds ANSI A118.4, A118.15 and A118.11 without the need for additives.

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Features/Benefits

Key Features

  • Fast curing - Grout in 3 hours, open for traffic in 4 hours
  • Unsurpassed bond strength and flexibility
  • Protects tile against cracks from surface movement up to 1/8"
  • Lightweight; Contains recycled content material that contributes to LEED® certification

Benefits

  • Sets quickly
  • Allows grouting in as little as 2-3 hours and light foot traffic in 4 hours
  • Maximum bond strength and flexibility
  • Isolates cracks to 1/8" (3 mm)
  • Non-slump medium bed for heavy tile and stone installations for floors and walls
  • Exceeds ANSI A118.4 and A118.11 standards without the need for additives

Technical/Installation

Applicable Standards

American National Standards Institute (ANSI) -

  • ANSI A108.5, A118.4, A118.15 and A118.11 of the American National Standards for the Installation of Ceramic Tile ASTM International (ASTM)
  • ASTM C109 Standard Test Method for Compressive Strength of Hydraulic Cement Mortars (Using 2-in. or [50-mm] Cube Specimens)
  • ASTM C627 Standard Test Method for Evaluating Ceramic Floor Tile Installation Systems Using the Robinson-Type Floor Tester
  • Resilient Floor Covering Institute — (RFCI) Recommended Work Practices for Removal of Resilient Floor Coverings

Tile Council of North America (TCNA) — TCNA Handbook for Ceramic Tile Installation, TCNA Method EJ171

Conformance to Building Codes

Installation must comply with the requirements of all applicable local, state and federal code jurisdictions.

Composition of Product

Modified dry mortar, which is a proprietary blend of Portland cement, inorganic aggregates, copolymers and chemicals.

Environmental Consideration

Custom® Building Products is committed to environmental responsibility in both products produced and in manufacturing practices. Use of this product can contribute towards LEED® v3 certification:

  • Up to 2 points towards MR Credit 5, Regional Materials
  • Up to 2 points towards MR Credit 4, Recycled Content
  • Up to 1 point towards IEQ Credit 4.1, Low-Emitting Materials – Adhesives & Sealants

Suitable Tile Types

  • Vitreous, semi-vitreous or non-vitreous tile: ceramic, mosaic, quarry, cement body tile
  • Impervious porcelain and glass tile
  • Brick and Stone Veneer
  • Cement-based precast terrazzo
  • Natural stone tile

Suitable Substrates

  • Concrete, mortar beds, masonry, Portland cement plaster
  • WonderBoard® Lite, cement backerboards
  • Liquid applied waterproofing membranes such as RedGard® and Custom® 9240
  • Crack prevention sheet membranes such as Crack Buster® Pro
  • Exterior Grade Plywood Substrates meeting deflection requirements (interior residential and light commercial dry areas)
  • Gypsum wallboard (interior dry areas)
  • Existing ceramic tile (scarified)
  • Fully bonded sheet vinyl flooring (scarified)
  • Plastic laminates (scarified)
  • Cutback adhesive (see preparation instructions)

General Surface Prep

Surfaces must be structurally sound. Remove all grease, oil, dirt, curing compounds, sealers, adhesives or any other contaminant that would prevent a good bond. Glossy or painted surfaces must be sanded, or abraded, and stripped of all contaminants. Concrete must be cured 28 days and accept water penetration. Concrete must be free of efflorescence and not subject to hydrostatic pressure. Concrete slabs should have a coarse finish to enhance the bond. Plywood flooring including those under resilient flooring must be structurally soundand meet all ANSI and deflection requirements. For questions about proper subfloor installation, call Technical Services. Smooth concrete surfaces, existing glazed tile, terrazzo, or polished stone should be scarified. Sheet vinyl must be well bonded and stripped of old finish. Roughen the surface by sanding or abrading, then rinse and allow to dry. Expansion joints should never be bridged with setting material. Do not sand flooring materials containing asbestos. Ambient temperature should be maintained above 50° F (10° C) or below 100° F (38° C) for 72 hours to achieve proper bond.  

Expansion Joint placement

Expansion joints and cold joints, as described in ANSI A108.01, should never be bridged with setting material. They must be brought through the tile work and filled with an appropriate elastomeric sealant, such as Custom's® 100% Silicone. Contact Custom's® Technical Services for the proper treatment of control or saw cut joints. Refer to TCNA EJ171, F125 and F125A.

Health Precautions

This product contains Portland cement and free silica. Avoid eye contact or prolonged contact with skin. Wash thoroughly after handling. If eye contact occurs, flush with water for 15 minutes and consult a physician. Do not breathe dust; wear a NIOSH approved respirator.

Limitations to the Product

  • Do not bond directly to hardwood, Luan plywood, particle board, parquet, cushion or sponge-back vinyl flooring, metal, fiberglass, plastic or OSB panels.
  • When setting moisture sensitive natural stone, cement or agglomerate tile use EBM-Lite™ Epoxy Bonding Mortar 100% Solids or CEG-Lite™ 100% Solids Commercial Epoxy Grout.
  • Do not use to install resin-backed stone use EBM-Lite™ Epoxy Bonding Mortar 100% Solids, CEG-Lite™ 100% Solids Commercial Epoxy Grout or contact Custom's® Technical Services for recommendations.
  • When setting glass tile larger than 6" x 6" (15 x 15 cm), contact Custom's® Technical Services for recommendations.
  • When setting dimensional stone larger than 12" x 12" (30 x 30 cm), contact Custom's® Technical Services for recommendations regarding subfloor deflection requirements.

Bonding to Concrete Surfaces

Concrete or plaster must be fully cured and must accept water penetration. Test by sprinkling water on various areas of the substrate. If water penetrates, then a good bond can be achieved; if water beads, surface contaminants are present, and loss of adhesion may occur. Contaminants should be mechanically removed before installation. Concrete must be free of efflorescence and not subject to hydrostatic pressure. Concrete slabs should have a coarse finish to enhance the bond. Smooth concrete slabs must be mechanically abraded to achieve proper bond.

Bonding to Lightweight Cement and Gypsum Surfaces

Lightweight or gypsum based underlayments must obtain a minimum 2000 psi (13.8 MPa) compressive strength. The underlayment must be sufficiently dry andproperly cured to the manufacturer’s specifications for permanent, non-moisture permeable coverings. Surfaces to be tiled must be structurally sound and subject to deflection not to exceed the current ANSI Standards. Surfaces shall be free of all grease, oil, dirt, dust, curing compounds, waxes, sealers, efflorescence, or any other foreign matter.

All Lightweight cement or Gypsum surfaces should be primed. with a properly applied sealer or a primer coat of RedGard, consisting of 1 part RedGard diluted with 4 parts clean, cool water. Mix in a clean bucket at low speed to obtain a lump free solution. The primer can be brushed, rolled or sprayed to achieve an even coat. Apply the primer coat to the floor at a rate of 300 ft2/gal (7.5 M2/L). Drying time depends on site conditions, but is normally less than 1 hour. Extremely porous surfaces may require 2 coats. At this point, RedGard can be applied to the primed lightweight or gypsum based surface. Refer to the individual product data sheet or packaging directions for application instructions. Expansion joints must be installed in accordance with local building codes and ANSI/TCNA guidelines. Refer to TCNA EJ171.

Bonding to Plywood Surfaces

Plywood floors, including those under resilient flooring, must be structurally sound and must meet all ANSI A108.01 Part 3.4 requirements. Maximum allowable deflection: L/360 tile L/720 stone. See TCNA F150-13 tile installations, TCNA F141-13 and F250-13 for stone. For questions about proper subfloor installation requirements, call Custom® Technical Services.

Bonding to Backerboards

As an alternative to an additional layer of plywood, WonderBoard Lite backerboard may be installed over plywood subfloors for ceramic tile installations. Refer to TCNA F144-13 tile installations and TCNA F-250-13 for stone. Call Custom® Technical Services when installing natural stone over plywood subfloor.

Bonding to Existing Surfacing Material

Existing Ceramic Tile, Resilient Flooring or Plastic Laminates: Resilient flooring or plastic laminates must be well bonded, as well as clean and free of all contaminates. Roughen the surface by sanding or scarifying; rinse and allow to dry. Do not sand flooring that contains asbestos. For existing well bonded ceramic tile, mechanically abrade the surface. Rinse and allow to dry. When sanding, an approved respirator should be used.

Bonding to Cutback Adhesive

Adhesive layers must be removed, as they reduce mortar bond strength to cement surfaces. Use extreme caution; adhesives may contain asbestos fibers. Do not sand or grind adhesive residue, as harmful dust may result. Never use adhesive removers or solvents, as they soften the adhesive and may cause it to penetrate into the concrete. Adhesive residue must be wet-scraped to the finished surface of the concrete, leaving only the transparent staining from the glue. To determine desirable results, do a test bond area before starting. Refer to the RFCI Pamphlet, "Recommended Work Practices for Removal of Resilient Floor Coverings", for further information.

Mixing Ratios

Mix 5.5 qt (5.21 L) clean water to 30 lb (13.6 kg) bag of mortar.

Mixing Procedures

Mix by hand or use a low 150-200 RPM speed 1/2" (13 mm) drill to achieve a smooth, paste-like consistency. Let the mixture slake or stand 5-10 minutes; stir again and use. Stir occasionally, but do not add more water. When properly mixed, troweled ridges will stand without slump.

Application of Product

Installation must conform to ANSI A108.5. Use a properly-sized notch trowel to ensure proper coverage under tiles. Using the flat side of the trowel, apply a skim coat of mortar to the surface. With the notch side of the trowel held at a 45° angle, apply additional mortar to the surface, combing in one direction. Press the tile firmly into place in a perpendicular motion across ridges, moving back and forth. The perpendicular motion flattens ridges and closes valleys, allowing maximum coverage. With some tile, back-buttering is advisable. Adjust the tile promptly and beat it in with a beating block and rubber mallet. Periodically pull up a tile and check the back to ensure proper adhesive coverage. If the material has skinned over (not sticky to the touch), recomb with the notch trowel; if too dry, remove and replace the dry material with fresh material. Thin-Set Mortar should not be used to fill low spots in the flooring. Mortar thickness should be less than 3/4" when beat in.

Curing of Product

Curing time is affected by ambient and surface temperatures and humidity. Use the following as a guideline. Allow 2 to 2.5 hours before grouting and 6 hours before light traffic. Submerged installations must cure for 14 days before filling with water.

Cleaning of equipment

Clean with water before the material dries.

Storage

Store in a cool dry area.

Product Maintenance

Properly installed product requires no special maintenance.

Expected Wear

Properly installed tile will last for more than 60 years.

Ordering Information

Packaging

  • 30 lb (13.6 kg) bag
  • Gray or white

Warranty Information

Product Warranty

Custom® Building Products warrants to the original consumer purchaser that its product shall be free from defects in material and workmanship under normal and proper usage for a period of one year following the date of original purchase. Custom's® sole liability under this warranty shall be limited to the replacement of the product. Some states, countries or territories do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This warranty will not extend to any product which has been modified in any way or which has not been used in accordance with Custom's® printed instructions. Custom® makes no other warranties either expressed or implied. This warranty gives you specific legal rights, and you may have other rights that vary from state to state or from one country/territory to another.  This warranty is not transferrable.

Warranty Duration

When MegaLite® Rapid Setting Crack Prevention Mortar is used as a part of a qualifying full installation system of CUSTOM products, the installation can qualify for up to a lifetime system warranty. CUSTOM will repair and/or replace, at its discretion, the affected area of the system. For more information, find details and limitations to this warranty at custombuildingproducts.com.

Coverage Chart

SQUARE FOOT COVERAGE PER 30 LB BAG (SQUARE METER PER 13.6 KG)

Trowel Size Min Coverage Max Coverage
1/4" x 1/4" x 1/4" (6 x 6 x 6 mm) Square-Notch 100 sq. ft. (9.3 M²) 110 sq. ft. (10.2 M²)
1/4" x 3/8" x 1/4" (6 x 9.5 x 6 mm) Square-Notch 70 sq. ft. (6.5 M²) 77 sq. ft. (7.2 M²)
1/2" x 1/2" x 1/2" (13 x 13 x 13 mm) Square-Notch 50 sq. ft. (4.6 M²) 55 sq. ft. (5.1 M²)
3/4" × 9/16" × 3/8" (19 × 14 × 9.5 mm) U-Notch 40 sq. ft. (33.7 M²) 44 sq. ft. (4.1 M²)

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