Detailed explanation of the entire process of thermal insulation mortar construction.-HPMC

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I. Overview of Core Construction Process

A standardized thermal insulation mortar construction process follows the following complete chain:

Construction Preparation → Substrate Treatment → Material Mixing → Layered Application → Curing → Protective Layer and Finish Coat Application

II. Step-by-Step Details and Technical Points

Step 1: Comprehensive Construction Preparation

Substrate Conditions: The wall surface must be firm, dry, free of oil stains and voids, and all embedded parts (such as pipelines) must be installed.

Environmental Conditions: During construction and for the following 24 hours, both the environment and wall surface temperature should not be lower than 5℃. Avoid working in rainy, windy, or direct sunlight conditions.

Technical Preparation: Mark horizontal and vertical control lines, and create thickness reference points (mortar dots) and guide strips with insulation mortar as required.

Step 2: Key Substrate Treatment

Cleaning and Wetting: Thoroughly remove dust and oil stains. Water the wall surface the day before construction to ensure the substrate is "internally wet and externally dry, without standing water."

Applying Bonding Agent: To enhance adhesion, a special bonding agent must be used. Mix evenly with a water-to-cement ratio of approximately 1:4, and apply or spray a thin, serrated layer (approximately 3mm thick) onto the wall surface.

Step 3: Material Mixing and Preparation

Accurate Proportioning: Strictly follow the product instructions for adding water. The common water-to-cement ratio for inorganic insulation mortar is approximately 1:1; for vitrified microsphere type, it is approximately 0.7-0.9 kg of water per 1 kg of powder.

Thorough Mixing: It is recommended to use an electric mixer, mixing for at least 3 minutes until a uniform, lump-free paste is formed. After standing for 3-5 minutes, stir briefly again before use. Never add water to already dried mortar for reuse.

Step 4: Core Layered Application

This is the core of quality control and must follow the principle of "layered application and layer-by-layer compaction."

Layer Thickness: The thickness of a single application should not exceed 20mm. If the total design thickness exceeds 20mm, it must be applied in two or more layers.

Time Interval: The interval between each application should be approximately 24 hours, and the next layer can only be applied after the previous layer of mortar has fully cured and does not deform when pressed by hand. Operating Procedure: The first layer should be applied with pressure to ensure firm adhesion to the base layer. Subsequent layers should be applied slightly higher than the screed lines, then leveled with a straightedge and smoothed with a wooden trowel, checking for verticality and flatness.

Step 5: Post-Construction Curing

Natural curing after construction is crucial.

Initial Curing: Within 24 hours after construction, water flushing, impact, or vibration are strictly prohibited.

Full Curing: After the overall construction of the insulation layer is completed, it needs to be cured by watering for at least 7 days. The specific time depends on the ambient temperature, and the surface should not turn white.

Step 6: Protective Layer and Special Area Treatment

Anti-Cracking Protective Layer: After the insulation layer has been properly cured, anti-seepage treatment and an anti-cracking protective layer are required. Typically, a layer of anti-cracking mortar is applied first, followed by pressing in alkali-resistant mesh fabric, and then another layer of anti-cracking mortar, with a total thickness of not less than 3mm.

Special Nodes:

Joint Treatment: When constructing at the junction of interior and exterior walls, the joint should be left on the interior wall, 600-800mm away from the inner and outer corners.

Kitchen and Bathroom Waterproofing: In damp areas such as kitchens and bathrooms, after the insulation layer is completed, a 5mm thick waterproof mortar layer or waterproof coating must be added to the surface.

III. Key Considerations

Thickness Control: The total thickness must meet the design requirements, which is a prerequisite for ensuring energy efficiency. This can be confirmed through sampling and testing.

Finished Product Protection: During the curing period and subsequent processes, protective measures such as waterproofing and protection against trampling must be taken for the completed insulation layer.

Seasonal Construction: Anti-freezing measures are required for winter construction; during high temperatures in summer, the mixed mortar should be used within 2-3 hours to prevent curing failure.

IV. Scheme Extension: How to ensure a foolproof plan?

The above is a highly versatile standard plan. To make the plan perfectly suit your project, you also need to pay special attention to:

Material Selection: Clearly identify whether cement-based or gypsum-based inorganic mortar is used, or mortar with different aggregates such as vitrified microspheres or expanded perlite, as their performance and construction details differ slightly.