formulation guidelines worldwide network for ...formulation guidelines for ternal® ev head office >...

TERNAL® EV needs to be formulated with one or a combination of rapid calcium sulfates such as semi-hydrate, gypsum or rapid anhydrite. Rapid kinetics of dissolution of the calcium sulfate is a key in creating a balanced hydration process that benefits from TERNAL® EV rapid dissolution.

Choosing the right calcium sulfate / TERNAL® EV ratio allows the engineering of optimum dimensional stability:

Once the calcium sulfate / TERNAL® EV ratio is set, it becomes the “core binder” for a range of formulations. The range of performance of flooring compounds sought is created by varying the content of the “core binder”. Different levels of performance, from cost effective to high performance, can be easily achieved with a single “core binder”.

An entire range can be developed as demonstrated in the chart below:

FORMULATION GUIDELINES

FOR TERNAL® EV

Head office

> FranceKerneos S.A8, rue des Graviers92521 Neuilly sur Seine CedexFranceTel.: +33 1 46 37 90 00Fax: +33 1 46 37 92 00

Research centers

> ChinaKerneos (China) AluminateTechnologies Co. Ltd86 Muning Road, Teda Tianjin, 300457 PR ChinaTel.: +86 22 5983 8300Fax: +86 22 6620 4481

> FranceKerneos Research Center1, rue Le ChatelierZAC Parc Technologique38090 Vaulx-Milieu - FranceTel.: +33 4 74 95 01 20Fax: +33 4 74 95 53 39

Plants

> Dunkerque - FrancePort 46904690 Route du Fortelet59279 Mardyck - FranceTel.: +33 3 28 58 00 00Fax: +33 3 28 58 00 01

> Fos-sur-Mer - FranceBP 2000113771 Fos-sur-Mer Cedex - FranceTel.: +33 4 42 06 91 00Fax: +33 4 42 06 91 14

> Le Teil - FranceRD 86 - BP 3207400 Le Teil - FranceTel.: +33 4 75 49 07 92Fax: +33 4 75 49 09 30

> United KingdomKerneos LimitedDolphin Way - PurfleetEssex RM19 1NZ - UKTel.: +44 1708 863333Fax: +44 1708 861033

> USA - CanadaKerneos Inc1316 Priority LaneChesapeake Virginia 23324 - USATel.: +1 757 284 3200Fax: +1 757 284 3300

> South America - BrazilKerneos do Brasil Produçaoe Comercio de Aluminosos LtdaEstrada de Guaxindiba, 150024722030 Sao Gonçalo RJ - BrazilTel.: +55 21 2602 3700Fax: +55 21 2601 3737

> South AfricaKerneos Southern Africa (Pty) Ltd20 Carbonode Cell, Alton IndustrialTownship, Richards BayP.O Box 613 Richards Bay 3900 - South AfricaTel.: +27 35 797 1000Fax: +27 35 797 1020


Commercial presence

> France - BeneluxKerneos S.AService Clients France BénéluxPort 46904690 Route du Fortelet59279 Mardyck - FranceTel.: + 33 3 28 58 93 73 / 77Fax: + 33 3 28 58 00 02


> GermanyKerneos GmbHCentroallee 275D-46047 Oberhausen - GermanyTel.: +49 208 63 59 0Fax: +49 208 63 59 171

> Nordic CountriesKerneos Nordic AB / Peramin ABJohanneslundsvägen 2SE - 194 81 Upplands VäsbySwedenTel.: + 46 8 5908 8020 / 6060Fax: + 46 8 5908 8025

> Eastern EuropeKerneos Polska Sp. z o.o.Al. Jerozolimskie 14802-326 Warszawa - PolandTel.: + 48 22 458 21 92Fax: + 48 22 458 21 94

> Russia & CISLCC KerneosShaumyana str. 4, block 1A,Office n°205195027 St. Petersburg - RussiaTel.: + 7 812 4489457Fax: + 7 812 4489456

> ItalyKerneos Italia S.R.L.Via Nino Bixio, 47/4920026 Novate Milanese (Milano) ItalyTel.: +39 02 43 00 631Fax: +39 02 48 16 517

> Spain - PortugalKerneos EspañaC/ Capitán Haya, n° 55 - 2° - 828020 Madrid - SpainTel.: +34 91 571 59 71Fax: +34 91 571 67 53

> TurkeyKerneos AlüminatDis Ticaret A.S.Sumko Sitesi M 1ABlok Daire 32Kozyatagi-KadikoyIstanbul 34736 - TurkeyTel.: + 90 216 373 0797/5833Fax: + 90 216 373 5156

> IndiaKerneos India3B - Shristi Bldg. / 3rd floor12, Ho Chi Minh SaraniKolkata 700 071 - IndiaTel.: + 91 33 3052 2315/16Fax: + 91 33 3052 2681

> Near & Middle EastKerneosUsine de Fos-sur-MerCellule Export - RN 568 - BP 113771 Fos-sur-Mer Cedex - FranceTel.: +33 4 42 06 91 15Fax: +33 4 42 06 91 91

> South AfricaKerneos Southern Africa (Pty) Ltd21 Dartfield Road, Eastgate Ext 12Sandton, 2148P.O Box 783602Sandton 2146 - South AfricaTel.: +27 11 444 3090Fax: +27 11 444 6575


> South AmericaKerneos do Brasil Produçaoe Comércio de Aluminosos LtdaEstrada de Guaxindiba 150024722030 Sao Gonçalo RJ - BrazilTel.: + 55 21 2602 3700Fax: + 55 21 2601 3737

> JapanKerneos JapanPrime Nihombashi Bldg.5FNihombashi Hamacho 3-35-6, Chuo-Ku,Tokyo 103-0007 - JapanTel.: +81 3 3667 7611Fax: +81 3 3667 3500

> ChinaKerneos (China) Aluminate Technologies Co.LtdBeijing Room 03-05, 22nd floor, Silver Tower,Dong San Huan Bei Lu, Chao Yang District,Beijing, 100027, P.R.ChinaTel.: + 86 10 64 10 8958/59Fax: + 86 10 6410 8966

> Singapore - South East AsiaKerneos Asia Pacific Pte Ltd230 Orchard Road# 09-236 Faber HouseSingapore 238854Tel.: +65 6737 3379Fax: +65 6734 8516

> AustraliaKerneos Australia Pty LtdLevel 4 7-9 Merriwa StreetP.O. Box 38Gordon NSW 2072 - AustraliaTel.: +61 2 9498 5288Fax: +61 2 9498 5311

Worldwide network Local presence

Head Office: 8, rue des Graviers • 92521 Neuilly-sur-Seine CedexTel.: +33(0)1 46 37 90 00 • Fax: +33 (0)1 46 37 92 00

For more information, visit us at:www.kerneos.com

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For flooring compounds

Middle range SLU

High range SLU/SLO

Performance Leveler

15% 45%30%“Core binder” content

MPa

1g2g

MPa

1g2g

Walk-on-time (*) ~ 24H < 2H

MPa

1g2g

MPa

1g2g

Coverage time (**) >24H ~ 2H

MPa

1g2g

MPa

1g2g

Mechanical strength (at 28 days) (*) ~ 15MPa> 50MPa

MPa

1g2g

MPa

1g2gWear resistance (H22/1,000 g/200 cycles/28 days) (*) Taber loss > 2g Taber loss < 1g

* Given values are indicative** Depends on the type of covering material

Fig 2: Variation of the different criteria of performance of self-leveling compounds versus the “core binder” content

Developing a range of flooring compounds

based on TERNAL® EV

The graph illustrates the impact of altering the ratio of calcium sulfate/TERNAL® EV on the dimensional stability.

1

0.8

0.6

0.4

0.2

0

-0.2

Time (hours)

Size

var

iatio

n (m

m/m

)

03:00 06:00 09:00 12:00 18:0015:00

CS / TERNAL® EV = 1.00Excessive expansion

CS / TERNAL® EV = 0.75Controlled expansion

CS / TERNAL® EV = 0.5Moderate shrinkage compensation

Fig 1: Size variation assessment of different formulations

Adjustment of the “core binder” content (based on a carefully defined combination of calcium sulfate and TERNAL® EV) allows the achievement of a wide range of performance. The binder content directly impacts each of the criteria that determines the performance of a self-leveling compound.

FOR FLOORING COMPOUNDS

Return to service is improved as “core binder” content is increased.

Coverage time is reduced with increased “core binder” content.

Long term mechanical strength improves with increased

“core binder” content.

Abrasion resistance improves with increased “core binder” content.

Fig 3: Variation of formulation setting time based on the “core binder” content variation

Fig 6: % of trapped water after 2 days versus

“core binder” content

Fig 7: Variation of compressive strength

with time for different self-leveling compounds

formulations

Fig 8: Taber test results versus


CONTINUOUS AND PREDICTABLE REACTIVITY

The reactivity, as measured by initial and final setting time, of TERNAL® EV-based binary self-leveling compounds

increases in a continuous and predictable way with “core binder” content and can be adjusted to a specific

performance by varying the additives percentage.

WALK-ON-TIME

COVERAGE TIME

MECHANICAL STRENGTH

ABRASION RESISTANCE

The walk-on-time decreases when the “core binder” content (based on a precisely defined combination of calcium sulfate and TERNAL® EV) increases as shown in the graph opposite.

Rapid drying, i.e. rapid crystallisation of water within ettringite, is essential

to ensure the residual moisture decreases to a sufficiently low level to allow the installation of floor coverings.

Drying speed increases with the binder content (at constant dosage of mixing

water), as shown by the amount of bound water after 2 days.

The level of strength can be easily adjusted by varying the “core binder” content.

The wear resistance varies also with the “core binder” content. The graph

displayed above gives the result of weight loss after Taber test (500 Taber cycles

(H22/1,000g)) for different self-leveling compounds. The abrasion resistance

of self-leveling compounds increases with the “core binder” content.

Fig 4: Evolution of walk-on-time versus “core binder” content variation

Early compressive and flexural strength both improve as “core binder content” is increased.

Self-leveling compounds need to achieve specific strengths before lightweight traffic can be allowed.

Fig 5: Compressive strength variation of different formulations based on TERNAL® EV

MPa

1g2g

MPa

1g2g

MPa

1g2g

MPa

1g2g

MPa

1g2g

MPa

1g2g

MPa

1g2g

MPa

1g2g

Reliable performance during application, across

a range of floor leveling compounds, is perhaps

one of the most difficult features to achieve in this

application. Each leveling compound in a range

normally needs to be formulated using multiple

binder components each introducing a significant

degree of complexity and variability.

With TERNAL® EV, an innovative calcium

aluminate binder, drymix producers can

efficiently develop an entire range of self-leveling

compounds with reliable and consistent

performance. Each of these products can be

developed with a single “core binder” composed

of a combination of TERNAL® EV and a suitable

calcium sulfate according to local availability.

With this “core binder” a wide range of compound

performance can be created cost effectively and a

range of self-levelers developed by the adjustment

of the quantity of “core binder” added to the

fillers that make up the bulk of typical formulations.

The usual range of additives should still be used to

tune specific performance.

TERNAL® EV based self-leveling underlayments

and overlayments provide an answer to many

trends in the flooring products industry. Issues

such as environmental performance through low

binder content, ultra fast return to service and the

creation of high performance materials can all be

addressed with TERNAL® EV.

140

120

100

80

60

40

20

0

TERNAL® EV (%) / Calcium Sulfate (%)

Water dosage = 24%

Initial Set

Final Set

Sett

ing

Tim

e (m

in)

20/10 16/8 12/6 8/4

MANAGING THE KEY PERFORMANCE CRITERIA

OF SELF-LEVELING COMPOUNDS

10

8

6

4

2

0

Wat

er b

oun

d in

hyd

rate

s (%

) (/

t in

itial

po

wd

er m

ix) a

fter

2 d

ays

hyd

ratio

n

15 20 25 30 3510Binder content (TERNAL® EV + CS) %

60

50

40

30

20

10

0

Co

mp

ress

ive

Stre

ngth

(MPa

)

Time

Water dosage = 24%storage at 23°C / 50% RH

28 days7 days24 hours6 hours2 hours

TERNAL® EV/CS: 20/10



TERNAL® EV/CS: 8/4

5

4

3

2

1

0

Wei

ght

loss

aft

er 5

00 c

ycle

s (g

)

17 19 21 23 25 27 29 3115

Binder content (TERNAL® EV + CS) %

6

5

4

3

2

1

0

Wal

k-o

n-tim

e (h

)

17 19 21 23 25 27 29 3115


12

10

8

6

4

2

0

Time ellapsed after mixing

Co

mp

ress

ive

Stre

ngth

(MPa

)

2 hours 6 hours 24 hours

Water dosage = 24%




TERNAL® EV/CS: 8/4

DEVELOPING A RANGE

OF FLOORING COMPOUNDS

FROM HIGH PERFORMANCE

TO COST-EFFECTIVE

FORMULATION GUIDELINES BASED ON TERNAL® EV

EconomicalLeveler

(%)

Mid-RangeLeveler

(%)

High-RangeLeveler

(%)

PerformanceLeveler

(%)

TERNAL® EV 8 12 16 20

Calcium Sulfate 4 6 8 10

Filler + sand Balance to 100%

Polymer powder 1 - 3 1 - 3 1 - 3 1 - 3

Retarder & Accelerator Usual type and dosage

Cellulosic ether Usual type and dosage

Peramin ® DEFOAM 51PE 0.1 0.1 0.1 0.1

Total 100 100 100 100

Water 24 24 24 24






FOR TERNAL® EV

Head office


Research centers



Plants









Commercial presence






















BCFL

OO

GB

803

2012

Pho

tos:

Ker

neos

/ C

orbi

s -

Des

ign

by: j

-cre

atio

n.fr


Middle range SLU

High range SLU/SLO

Performance Leveler


MPa

1g2g

MPa

1g2g


MPa

1g2g

MPa

1g2g


MPa

1g2g

MPa

1g2g


MPa

1g2g

MPa







1

0.8

0.6

0.4

0.2

0

-0.2

Time (hours)

Size

var

iatio

n (m

m/m

)

03:00 06:00 09:00 12:00 18:0015:00





Adjustment of the “core binder” content (based on a carefully defined combination of calcium sulfate and TERNAL® EV) allows the achievement of a wide range of performance. The binder content directly impacts each of the criteria that determines the performance of a self-leveling compound.

FOR FLOORING COMPOUNDS

Return to service is improved as “core binder” content is increased.

Coverage time is reduced with increased “core binder” content.

Long term mechanical strength improves with increased

“core binder” content.

Abrasion resistance improves with increased “core binder” content.

Fig 3: Variation of formulation setting time based on the “core binder” content variation

Fig 6: % of trapped water after 2 days versus


Fig 7: Variation of compressive strength

with time for different self-leveling compounds

formulations

Fig 8: Taber test results versus


CONTINUOUS AND PREDICTABLE REACTIVITY

The reactivity, as measured by initial and final setting time, of TERNAL® EV-based binary self-leveling compounds

increases in a continuous and predictable way with “core binder” content and can be adjusted to a specific

performance by varying the additives percentage.

WALK-ON-TIME

COVERAGE TIME

MECHANICAL STRENGTH

ABRASION RESISTANCE

The walk-on-time decreases when the “core binder” content (based on a precisely defined combination of calcium sulfate and TERNAL® EV) increases as shown in the graph opposite.

Rapid drying, i.e. rapid crystallisation of water within ettringite, is essential

to ensure the residual moisture decreases to a sufficiently low level to allow the installation of floor coverings.

Drying speed increases with the binder content (at constant dosage of mixing

water), as shown by the amount of bound water after 2 days.

The level of strength can be easily adjusted by varying the “core binder” content.

The wear resistance varies also with the “core binder” content. The graph

displayed above gives the result of weight loss after Taber test (500 Taber cycles

(H22/1,000g)) for different self-leveling compounds. The abrasion resistance

of self-leveling compounds increases with the “core binder” content.

Fig 4: Evolution of walk-on-time versus “core binder” content variation

Early compressive and flexural strength both improve as “core binder content” is increased.

Self-leveling compounds need to achieve specific strengths before lightweight traffic can be allowed.

Fig 5: Compressive strength variation of different formulations based on TERNAL® EV

MPa

1g2g

MPa

1g2g

MPa

1g2g

MPa

1g2g

MPa

1g2g

MPa

1g2g

MPa

1g2g

MPa

1g2g

Reliable performance during application, across

a range of floor leveling compounds, is perhaps

one of the most difficult features to achieve in this

application. Each leveling compound in a range

normally needs to be formulated using multiple

binder components each introducing a significant

degree of complexity and variability.

With TERNAL® EV, an innovative calcium

aluminate binder, drymix producers can

efficiently develop an entire range of self-leveling

compounds with reliable and consistent

performance. Each of these products can be

developed with a single “core binder” composed

of a combination of TERNAL® EV and a suitable

calcium sulfate according to local availability.

With this “core binder” a wide range of compound

performance can be created cost effectively and a

range of self-levelers developed by the adjustment

of the quantity of “core binder” added to the

fillers that make up the bulk of typical formulations.

The usual range of additives should still be used to

tune specific performance.

TERNAL® EV based self-leveling underlayments

and overlayments provide an answer to many

trends in the flooring products industry. Issues

such as environmental performance through low

binder content, ultra fast return to service and the

creation of high performance materials can all be

addressed with TERNAL® EV.

140

120

100

80

60

40

20

0

TERNAL® EV (%) / Calcium Sulfate (%)

Water dosage = 24%

Initial Set

Final Set

Sett

ing

Tim

e (m

in)

20/10 16/8 12/6 8/4

MANAGING THE KEY PERFORMANCE CRITERIA

OF SELF-LEVELING COMPOUNDS

10

8

6

4

2

0

Wat

er b

oun

d in

hyd

rate

s (%

) (/

t in

itial

po

wd

er m

ix) a

fter

2 d

ays

hyd

ratio

n

15 20 25 30 3510Binder content (TERNAL® EV + CS) %

60

50

40

30

20

10

0

Co

mp

ress

ive

Stre

ngth

(MPa

)

Time

Water dosage = 24%storage at 23°C / 50% RH

28 days7 days24 hours6 hours2 hours




TERNAL® EV/CS: 8/4

5

4

3

2

1

0

Wei

ght

loss

aft

er 5

00 c

ycle

s (g

)

17 19 21 23 25 27 29 3115


6

5

4

3

2

1

0

Wal

k-o

n-tim

e (h

)

17 19 21 23 25 27 29 3115


12

10

8

6

4

2

0

Time ellapsed after mixing

Co

mp

ress

ive

Stre

ngth

(MPa

)

2 hours 6 hours 24 hours

Water dosage = 24%




TERNAL® EV/CS: 8/4

DEVELOPING A RANGE

OF FLOORING COMPOUNDS

FROM HIGH PERFORMANCE

TO COST-EFFECTIVE

FORMULATION GUIDELINES BASED ON TERNAL® EV

EconomicalLeveler

(%)

Mid-RangeLeveler

(%)

High-RangeLeveler

(%)

PerformanceLeveler

(%)

TERNAL® EV 8 12 16 20

Calcium Sulfate 4 6 8 10

Filler + sand Balance to 100%

Polymer powder 1 - 3 1 - 3 1 - 3 1 - 3

Retarder & Accelerator Usual type and dosage

Cellulosic ether Usual type and dosage

Peramin ® DEFOAM 51PE 0.1 0.1 0.1 0.1

Total 100 100 100 100

Water 24 24 24 24






FOR TERNAL® EV

Head office


Research centers



Plants









Commercial presence






















BCFL

OO

GB

803

2012

Pho

tos:

Ker

neos

/ C

orbi

s -

Des

ign

by: j

-cre

atio

n.fr


Middle range SLU

High range SLU/SLO

Performance Leveler


MPa

1g2g

MPa

1g2g


MPa

1g2g

MPa

1g2g


MPa

1g2g

MPa

1g2g


MPa

1g2g

MPa







1

0.8

0.6

0.4

0.2

0

-0.2

Time (hours)

Size

var

iatio

n (m

m/m

)

03:00 06:00 09:00 12:00 18:0015:00





formulation guidelines worldwide network for ...formulation guidelines for ternal® ev head office >...

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