Construction process for paving new ceramic tiles on surfaces of old ceramic tiles

Abstract

The invention belongs to the field of building decoration construction, particularly relates to a construction process for paving new ceramic tiles on the surfaces of old ceramic tiles, and solves the problem of insufficient binding power of direct tiling on the surfaces of the old ceramic tiles. The construction process comprises the following steps: (1) polishing the surface of an old ceramic tile to remove a glaze layer of the old ceramic tile so as to form a first rough surface; (2) coating the first rough surface with an interface agent, and performing galling treatment on the formed interface agent layer to form a second rough surface; (3) respectively coating the second rough surface and the back surface of the new ceramic tile with a ceramic tile adhesive; and (4) the new ceramic tiles are laid on the second rough surface, air between the ceramic tile adhesives is discharged through kneading and pressing, and full-slurry pasting is achieved. Through double roughening treatment of mechanical polishing and interface agent galling, a composite mechanical occlusion interface is constructed, the bonding strength is remarkably improved, the problem of infirm bonding is solved, and the method has the advantages of being safe, reliable, controllable in quality, efficient and environmentally friendly.

Description

Technical Field

[0001] This invention belongs to the field of building decoration construction, and specifically relates to a construction process for laying new tiles on the surface of old ceramic tiles. Background Technology

[0002] In old house renovation and interior refurbishment projects, renovating tiled walls and floors in spaces such as bathrooms and kitchens is a common need. Traditional renovation methods usually require completely removing the old tile layer before leveling, waterproofing, and re-tiling the walls. This traditional method has many drawbacks: First, the removal work is time-consuming and labor-intensive, with a long construction period, and generates a large amount of construction waste, increasing disposal costs and environmental burden; second, the vibrations during the demolition process can easily damage water and electricity pipes inside the wall or destroy the original waterproof layer, causing secondary problems such as leaks; finally, the construction process generates loud noise and a lot of dust, seriously affecting the living environment.

[0003] To circumvent the aforementioned problems, the industry has attempted to directly lay new tiles on top of old ones. However, because the glaze of old tiles is typically very smooth, dense, and has extremely low water absorption, traditional cement-based adhesives struggle to form an effective mechanical bond on their surface. To enhance adhesion, existing technologies have proposed applying an interface agent to the substrate and roughening the surface before the agent initially sets. However, this method is primarily applicable to substrates such as concrete, which inherently possess some water absorption and roughness. When applied directly to the smooth, dense, and almost non-absorbent glaze of old tiles, the mechanical bonding force provided by roughening with an interface agent alone is still limited, making it difficult for the adhesive to form a strong bond with the smooth glaze. Therefore, newly laid tiles still pose a safety hazard after long-term use due to insufficient bonding strength, leading to hollowing, loosening, or even detachment. Furthermore, existing processes often lack unified and standardized construction standards, and the quality of construction highly depends on the individual experience of workers, resulting in poor stability.

[0004] Therefore, based on this, the technical solution of the present invention is proposed. Summary of the Invention

[0005] The purpose of this invention is to provide a construction process for laying tiles on old ceramic tile surfaces based on double roughening treatment. This aims to solve the technical problem in the prior art where new tiles are easily hollowed out and fall off due to insufficient adhesion when directly laying new tiles on smooth, low-absorption old ceramic tile surfaces. The invention also provides a standardized, high-quality, and high-efficiency construction method.

[0006] To achieve the above objectives, the present invention provides a construction process for laying new tiles on the surface of old ceramic tiles, the construction process comprising the following steps:

[0007] (1) Grind the surface of the old ceramic tile to remove its glaze layer and form the first rough surface; (2) Apply an interface agent to the first rough surface and roughen the resulting interface agent layer to form a second rough surface; (3) Apply tile adhesive to the second roughened surface and the back of the new tile respectively; (4) The new ceramic tile is laid on the second rough surface and the air between the ceramic tile adhesive is expelled by kneading to achieve full adhesion.

[0008] Preferably, in step (1), the grinding process is performed by using an angle grinder or a sandblasting machine to treat the surface of the old ceramic tile.

[0009] Preferably, in step (2), the texturing process is performed by using a texturing roller or texturing brush to process the interface agent layer before the interface agent initially sets, so as to form an uneven texture on the surface of the interface agent layer.

[0010] Preferably, in step (3), a notched trowel is used to comb the tile adhesive into parallel serrations on the second rough surface and the back of the new tile, respectively.

[0011] Preferably, in step (4), the direction of the adhesive tooth marks on the back of the new tile is kept parallel to the direction of the adhesive tooth marks on the second rough surface; and the new tile is kneaded in a direction perpendicular to the adhesive tooth marks.

[0012] Preferably, in step (4), the air is expelled by using a handheld tile leveling vibrator to vibrate the new tile.

[0013] Preferably, before the polishing process, the old tiles are pre-treated, which includes: reinforcing or repairing loose or damaged old tiles, and cleaning the surface of the old tiles.

[0014] Preferably, the interface agent is a polymer-modified interface agent; the tile adhesive is a cement-based tile adhesive.

[0015] Preferably, the thickness of the adhesive layer formed between the new ceramic tile and the second roughened surface is 4-8 mm.

[0016] Preferably, after all the new tiles have been laid, the tile adhesive is cured, and grouting is performed after the tile adhesive has reached a preset strength.

[0017] The beneficial effects of this invention are as follows: 1. High bonding strength and reliable safety. Through the dual roughening treatment of "mechanical grinding" and "interface agent roughening", a composite rough interface with a dual locking effect is constructed on the smooth surface of old tiles, which greatly improves the mechanical bonding force of the adhesive, fundamentally solves the problem of weak bonding, and effectively avoids the hollowing and falling off of new tiles.

[0018] 2. Standardized process and controllable quality. This invention provides a complete and clear construction process, including key control points such as double-sided adhesive application, parallel adhesive distribution, and vertical pressing, reducing reliance on the experience of construction personnel and ensuring the stability and consistency of construction quality.

[0019] 3. Highly efficient construction and cost-saving. By eliminating the tedious processes of removing old bricks, clearing garbage, and leveling the surface, the construction cycle can be significantly shortened, reducing labor, material, and time costs.

[0020] 4. Green and environmentally friendly. This process avoids the large amount of construction waste, noise, and dust pollution generated by smashing old bricks, meeting the requirements of green construction in modern buildings. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be described in detail below. Obviously, the described embodiments are merely some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0022] Example 1 This embodiment provides a construction process for directly laying new tiles on existing old tile surfaces. Specifically, this process involves double roughening the old tile substrate and combining it with a standardized thin-set application method to create a high-strength, durable, and reliable composite mechanical interlocking interface. This solves the technical problem of hollow spots and detachment that easily occur when directly laying new tiles on smooth old tile surfaces.

[0023] The process mainly includes: substrate assessment and treatment step S1, mechanical grinding step S2, interface agent roughening step S3, double-sided adhesive coating step S4, laying and pressing to remove air step S5, and curing and grouting step S6. To better understand the technical solution of this invention, a specific construction scenario applied to the renovation of residential bathroom walls will be described in detail below.

[0024] Step S1 involves base layer assessment and treatment. Before formal construction, a comprehensive inspection of the old tiled wall surface, which serves as the base, is required. Construction workers can use a sounding hammer or knuckles to tap each old tile on the wall, judging by the sound to determine if there are any hollow or loose tiles. In this embodiment, if hollow tiles are found, they should be carefully removed using an electric hammer or flat chisel, and any remaining loose mortar should be cleaned away. Subsequently, cement mortar with a grade no lower than M10 is used to repair the pits formed after the tiles were removed, and a scraper is used to ensure the repaired area is flush with the surrounding wall surface. After the cement mortar has reached sufficient strength and is completely dry, and after confirming that all old tiles are firmly in place, surface cleaning is carried out. It is understood that bathroom walls may have contaminants such as limescale, soap scum, and grease, which can severely affect the adhesion of subsequent materials. Therefore, a special cleaning agent should be used with a scouring pad or wire brush to thoroughly scrub the entire old tiled wall surface to completely remove all dirt. Finally, rinse thoroughly with clean water and allow it to dry completely. This pretreatment step ensures the stability and cleanliness of the construction substrate, which is the foundation for the success of subsequent processes.

[0025] The subsequent step, S2, is mechanical sanding. The purpose of this step is to physically break down the smooth, dense glaze layer on the surface of the old tiles, providing a rough adhesion base for subsequent bonding. Workers can use a handheld angle grinder equipped with diamond grinding discs, and after taking personal protective measures, to systematically sand the entire surface of the old tile wall. During sanding, the grinding disc should be kept at a small acute angle to the wall and moved at a uniform speed to ensure that every glaze is effectively removed. The standard for successful sanding is that the entire wall surface no longer has a reflective sheen, and the surface has a uniform, frosted glass-like matte roughness, with a rough feel. At this point, the surface of the old tile substrate has formed the first roughened surface. The sanding process generates a large amount of dust, and a high-powered industrial vacuum cleaner must be used to thoroughly vacuum the wall from top to bottom to ensure that no dust residue remains in the pores of the first roughened surface, preparing it for the next step.

[0026] The interface agent roughening step S3 aims to construct a second roughening structure based on the first roughened surface through a combination of chemical bonding and physical locking. In one embodiment of the invention, a high-performance polymer-modified interface agent is selected, which has high permeability, high bonding strength, and excellent bidirectional bonding performance, enabling it to simultaneously and firmly bond to both the low-water-absorption ceramic tile body and the subsequent cement-based adhesive. The construction personnel prepare the interface agent according to the product instructions. For example, for a two-component powder-liquid product, the liquid component is first poured into a clean mixing tank, then the powder component is slowly added while simultaneously stirring with a low-speed electric mixer (speed below 500 rpm) until a uniform, lump-free slurry is formed.

[0027] Subsequently, using a short-pile roller, the interface agent is evenly applied to the cleaned first roughened surface 2, ensuring a consistent thickness and avoiding any missed spots or drips. A crucial step is to perform the roughening process immediately while the interface agent layer is still wet and not yet fully set. The applicator uses a specialized roughening roller, rolling it back and forth on the freshly applied interface agent surface with moderate pressure to create numerous dense, disordered, and appropriately deep uneven textures or spike-like protrusions. After the interface agent cures, these textures form a second roughened surface with a significantly uneven structure. This second roughened surface provides numerous mechanical anchoring points for the subsequent tile adhesive, greatly enhancing mechanical bonding strength. After roughening, the interface agent layer should be allowed to air dry naturally until its surface is dry to the touch and not sticky.

[0028] Step S4 involves applying adhesive to both sides. This step is crucial for ensuring a full, seamless bond between the new tiles and the wall. This embodiment uses a high-performance cement-based tile adhesive that meets the C2 standard, which offers higher bonding strength and better flexibility. The installer first prepares the adhesive by mixing the dry powder with water in the ratio recommended on the product packaging (approximately 4:1 in this example). Using an electric mixer, mix thoroughly for about 2-3 minutes, let it stand for about 3-5 minutes to mature, and then mix briefly a second time (about 1 minute) before use.

[0029] The construction workers used a "double-sided adhesive application method," which involves simultaneously applying adhesive to both the wall surface (the surface with the second roughened layer) and the back of the new tiles to be laid (600×1200mm in this example). The specific procedure is as follows: using a notched trowel with 10mm deep teeth, first, using its smooth side, apply a suitable amount of prepared tile adhesive to the wall surface to form a thin base coat. Then, add sufficient adhesive, holding the notched trowel at an angle of approximately 45° to 60° to the wall surface, and forcefully comb the adhesive to create evenly thick, full, and parallel adhesive notches. Correspondingly, the same operation is performed on the back of the new tiles, combing out parallel adhesive notches in the same direction.

[0030] In step S5, which involves laying and pressing to release air, the installer aligns the new tile, with the adhesive already applied to its back, with the desired placement on the wall. As a preferred technique, the direction of the adhesive notches on the back of the new tile should be parallel to the direction of the adhesive notches on the wall. After placing the tile on the wall, immediately press and vibrate it in a direction perpendicular to the adhesive notches. Proper pressing causes the parallel adhesive notches to spread outwards and merge, effectively squeezing out any air trapped between the notches. This parallel adhesive application and vertical pressing method ensures a gapless adhesive layer, achieving full adhesion. While pressing, a spirit level is used to check the tile's flatness, and 2mm thick cross-shaped positioning clips are used to ensure uniform gap width. After pressing, the final adhesive layer thickness is controlled between 4-8mm; in this example, it is approximately 5mm.

[0031] The final step, S6, is curing and grouting. After all the new tiles have been laid, the entire wall surface must be protected from any vibration or impact, and the tile adhesive must be allowed to cure naturally for at least 24 hours. Once the adhesive has reached sufficient initial strength, the cross clips can be removed, and subsequent grouting work can be carried out to complete the renovation of the entire wall surface.

[0032] Example 2 As an optional implementation, this embodiment provides a variation of the construction process, the main difference from Embodiment 1 being the specific implementation of the mechanical grinding step S2. In this embodiment, sandblasting is used instead of angle grinder grinding to obtain a more uniform and microscopic rough surface.

[0033] The basic assessment and processing steps S1 in this embodiment are exactly the same as those in Embodiment 1.

[0034] When performing mechanical grinding step S2, the workers must first fully protect the non-work areas to prevent contamination and damage from the abrasive. After donning full protective gear, a portable pressure sandblasting machine is used, employing appropriately sized quartz sand or corundum as the abrasive, to systematically blast the surface of the old tiles. The endpoint criterion for sandblasting is similar to that in Example 1: the smooth glaze layer on the surface of the old tiles is completely removed, resulting in a uniform frosted or sandblasted appearance. Compared to angle grinder grinding, sandblasting produces a more uniform and finer rough surface at the microscopic scale—the first rough surface—which has a larger specific surface area and more numerous micro-anchoring points. After the work is completed, the site must be thoroughly cleaned, and an industrial vacuum cleaner must be used to remove dust from the walls.

[0035] The subsequent interface agent roughening step S3, double-sided adhesive coating step S4, laying and pressing air release step S5, and curing and grouting step S6 all use the same materials, tools and specific operating methods as described in Example 1, and ultimately form a strong bonded structure.

[0036] Example 3 In this embodiment, different interface agent texturing methods can also be used in the construction process. The difference between the variant provided in this embodiment and Embodiment 1 lies in the specific implementation of the interface agent texturing step S3. In this embodiment, a stiff-bristled texturing brush is used instead of a texturing roller to create deeper and more directional groove-like textures.

[0037] The base assessment and treatment step S1 and the mechanical grinding step S2 in this embodiment are exactly the same as those in Embodiment 1.

[0038] In step S3 of the interface agent roughening process, the selection, preparation, and application method of the interface agent are the same as in Example 1. After the interface agent is evenly applied to the first roughened surface, the worker immediately uses a roughening brush made of stiff nylon or metal wire to drag and brush the wet interface agent layer in a single direction or in a crisscross or disordered manner. Unlike the texture created by a roughening roller, the roughening brush can scrape deeper and more clearly defined grooves, giving the cured second roughened surface a three-dimensional structure similar to dovetail grooves. When the subsequent tile adhesive fills these grooves and cures, it forms a strong three-dimensional wedge-shaped locking effect, thereby effectively resisting pull-out and shear forces.

[0039] The subsequent steps of applying adhesive on both sides (S4), laying and pressing to remove air (S5), and curing and filling (S6) are performed in exactly the same way as in Example 1, ultimately forming a strong bonded structure.

[0040] Example 4 This embodiment provides an optimized solution for the laying and pressing / air-venting step S5, which is particularly suitable for laying large-sized tiles or thin tile slabs. In this embodiment, a handheld tile leveling vibrator is used to assist in pressing and air-venting, achieving a more efficient and reliable full-grout adhesion effect.

[0041] The preliminary steps of this embodiment, including S1, S2, S3 and S4, can all be performed in any combination of the methods described in Embodiments 1, 2 or 3.

[0042] This embodiment is set to the scenario of laying large-sized thin ceramic tile slabs of 600x1200mm. Due to the large size of the tiles, it is difficult to ensure complete air removal in the central area by manually pressing and kneading. During the laying and air-removing step S5, after the large-sized new tiles are initially attached to the wall, a handheld tile leveling vibrator is used. This device is usually equipped with a suction cup and an adjustable frequency vibration motor.

[0043] The installer firmly attaches the vibrator's suction cup to the center of the tile and activates the vibration function. The high-frequency vibration causes the adhesive grout to "liquefy," instantly increasing its fluidity and automatically filling tiny gaps while quickly expelling trapped air. The installer then holds the vibrator and slowly moves it from the center of the tile to each corner and edge, ensuring the entire tile is fully vibrated. The vibrator's suction cup also allows for easy fine-tuning and leveling of the tile's position. This process not only reduces labor intensity but also ensures more thorough air removal and a higher grout coverage.

[0044] After using a vibrator to assist in pressing, the final adhesive layer thickness should be controlled within a reasonable range of 4-8mm, and positioning clips should be used to ensure uniform gaps. Subsequent curing and grouting steps S6 are the same as in Example 1.

[0045] In summary, the construction process disclosed in this invention, through a dual roughening core technology consisting of mechanical grinding and interface agent roughening, combined with standardized double-sided adhesive application and kneading and degassing processes, can construct an extremely strong composite bonding system on the smooth surface of old ceramic tiles. This technical solution fundamentally solves the major technical challenge of tile-on-tile bonding in old house renovation, and has significant advantages such as high bonding strength, stable construction quality, high efficiency, and environmental friendliness.

[0046] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A construction process for laying new tiles on the surface of old ceramic tiles, characterized in that, The construction process includes the following steps: (1) Grind the surface of the old ceramic tile to remove its glaze layer and form the first rough surface; (2) Apply an interface agent to the first rough surface and roughen the resulting interface agent layer to form a second rough surface; (3) Apply tile adhesive to the second roughened surface and the back of the new tile respectively; (4) The new ceramic tile is laid on the second rough surface and the air between the ceramic tile adhesive is expelled by kneading to achieve full adhesion.

2. The construction process for laying new tiles on the surface of old ceramic tiles according to claim 1, characterized in that, In step (1), the grinding process is performed by using an angle grinder or a sandblasting machine to treat the surface of the old ceramic tile.

3. The construction process for laying new tiles on the surface of old ceramic tiles according to claim 1, characterized in that, In step (2), the texturing process is as follows: before the interface agent initially sets, the interface agent layer is treated with a texturing roller or a texturing brush to form an uneven texture on the surface of the interface agent layer.

4. The construction process for laying new tiles on the surface of old ceramic tiles according to claim 1, characterized in that, In step (3), a notched trowel is used to comb the tile adhesive into parallel serrations on the second rough surface and the back of the new tile, respectively.

5. The construction process for laying new tiles on the surface of old ceramic tiles according to claim 4, characterized in that, In step (4), the direction of the adhesive tooth marks on the back of the new tile is kept parallel to the direction of the adhesive tooth marks on the second rough surface; and the new tile is kneaded in a direction perpendicular to the adhesive tooth marks.

6. The construction process for laying new tiles on the surface of old ceramic tiles according to claim 1, characterized in that, In step (4), the air is expelled by using a handheld tile leveling vibrator to vibrate the new tile.

7. The construction process for laying new tiles on the surface of old ceramic tiles according to claim 1, characterized in that, Before the polishing process, the old tiles are pre-treated, which includes reinforcing or repairing loose or damaged old tiles and cleaning the surface of the old tiles.

8. The construction process according to claim 1, characterized in that, The interface agent is a polymer-modified interface agent; the tile adhesive is a cement-based tile adhesive.

9. The construction process according to claim 1, characterized in that, The thickness of the adhesive layer formed between the new ceramic tile and the second roughened surface is 4-8 mm.

10. The construction process according to claim 1, characterized in that, After all the new tiles have been laid, the tile adhesive is cured and then grouting is performed once the tile adhesive has reached the preset strength.