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Unread 10-18-2020, 05:32 PM   #1
Sauvanto
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Help! Ceramic popped off

After 48 hours of curing, two ceramics popped off. What do I do now?
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Unread 10-18-2020, 06:08 PM   #2
jadnashua
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See all of those ridges on the floor? The larger the tile, the harder it is to compress those flat so you get good coverage. Industry calls for 100% of the edges and at least 90% of the back to be covered once set. The tile was back buttered, which is good, but it also might have been done too far in advance, or the same with the floor, so the thinset has skinned over before you've tried to set it.
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Unread 10-18-2020, 06:32 PM   #3
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Welcome to the forum, Sauvanto!

For a dry area, the required industry minimum mortar coverage is actually only 80%. You’ve obtained that on the right side of the picture. But are at about 75% in the middle, and maybe 60% on the left side.

With the tile coming off so clean, I’d be very suspicious of the mortar skinning over, like Jim mentioned. If you lightly touch the ribbons of troweled mortar with your finger (just before placing a tile), you should get some mortar transfer. If you finger comes away clean, the mortar has started skinning over and needs to be refreshed. Any chance of this?

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Unread 10-18-2020, 08:10 PM   #4
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What is the substrate?
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Unread 10-18-2020, 09:32 PM   #5
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your floor might be out of plane and the lash clips pulled the tile up out of the thinset, resulting in not collapsing the ridges
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Unread 10-19-2020, 10:06 AM   #6
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Thanks all for the insight!

The floor is exterior grade high quality plywood leveled within 1/8th of an inch, and we used the Mapei 2-hours-cure cement.

What should I do to cement those two particular tiles back in place?
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Unread 10-19-2020, 12:28 PM   #7
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Did you tile directly to the plywood?

And you used a rapid setting mortar?
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Unread 10-19-2020, 12:49 PM   #8
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Yes they are tiled directly onto the plywood, and the mortar is Mapei Ultraflex 2 Professional (24-hour safe for light traffic)
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Unread 10-19-2020, 12:55 PM   #9
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FWIW, industry standards call for two layers of plywood when tiling directly to it, and an appropriate thinset. If I were to guess, not discounting the fact that there's not enough coverage, the thinset was getting too close to firing off when those tile were installed, IOW, it was already nearly cured. Being near or at the end of the pot life with the thinset means it is much thicker, and thus harder to embed the tile properly.
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Unread 10-19-2020, 01:04 PM   #10
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If we were to assume that the subfloor was adequate as described by Jim, you'd still have to work lightning fast to to cover that mortar before it went off.

I've set a lot of tile, but I don't use rapid setting mortar unless it's a very small area, or just setting a few tiles. And even then I have all the tile pre-cut and ready to set in place before I even mix up the mortar.

Of course if you have a single layer plywood or OSB subfloor, that's another issue.
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Unread 10-21-2020, 07:55 AM   #11
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Ultra flex 2 is not a rapid setting mortar, it does have a 2 hour pot life.

https://cdnmedia.mapei.com/docs/libr...rsn=373d6259_0

to reset those 2 tiles you should remove the old mortar, and start fresh with new mortar. and install the tiles.

Good luck.
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Unread 10-21-2020, 09:53 PM   #12
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If you've installed the tile over single-layer plywood, you can expect to see this some more.

Plywood will also draw the moisture out of the mortar prematurely, and I think that's what caused the issue at hand. Wiping the floor with a damp sponge immediately before putting mortar down would have probably helped.
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Unread 10-21-2020, 11:22 PM   #13
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Yes, we really need to know if this is a single or multi-layer ply floor. Please tell us all the layers and the thickness of each.

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Unread 10-22-2020, 07:13 AM   #14
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Have you tried with your fingers or a putty knife, to see if any of the adjacent tiles want to pop off too?
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Unread 10-22-2020, 06:06 PM   #15
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I agree with Randy, I'd lightly pry on some of them.

To lighten the leveling wedges, you have to have the neighboring tiles set. By then the thinset can skin over.
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