Mapei at the Brisbane International Airport Terminal

After two years of construction and an investment of over $340 million, Brisbane Airport Corporation completed the Brisbane International Terminal expansion in December 2008. The upgrade includes extensions to both the Northern and Southern ends of the terminal, increasing total floor space by 33,000 m2 to include additional retail, customs, security, baggage and lounge areas. Also incorporated into the new design were dual aerobridges to cater for the super wide-bodied A380 aircraft.

The expansion of the airport created a milestone for Mapei Australia. Due to the success of the tiling installation in the original terminal fourteen years earlier, Mapei products were again preferred for the new expansion project. This achievement symbolises the quality, performance and reliability of Mapei products and the testimony that Mapei products have endured enormous amounts of demanding pedestrian and trolley traffic over an extended period of time.

Work commenced in 2006 with the removal of existing retail shops to allow for the expansion of the terminal. This demolition work resulted in damage to the existing flooring that required Mapei's Nivorapid to level and patch the substrate where existing tiles, carpet and timber floor coverings had been removed. Nivorapid is a fast setting and rapid hardening repair and smoothing mortar for horizontal and vertical surfaces that is easily workable with a high bond strength and can be covered within 4-6 hours.

Mapei's Ultraplan self-levelling compound was applied to approx 11000 m2 of the new and existing flooring to ensure level consistency with added benefits of high compressive and flexural strength as well as high resistance to abrasive traffic. The use of Ultraplan ensures a solid substrate that can be covered 12 hours after installation. The prerequisite required for the tiling installation required a tiling installation for use within 36 hours. This timeframe was achieved through the use of Mapei's high quality, rapid setting flooring products.

The tiling contractors applied Mapei's Primer G to the concrete substrate before applying Mapegum WPS to all new flooring to perform as a crack isolation membrane. The flexibility of Mapegum WPS enables it to withstand normal expansion and contraction movements in the substrate which makes it a perfect anti-fracture membrane for substrates which are subject to light cracking (1mm). Mapegum WPS can be applied by trowel, brush, roller or spray and creates an excellent flexible membrane which is strong enough to withstand light pedestrian traffic prior to the tiling being installed. Mapegum WPS also forms an excellent surface which bonds perfectly to adhesives used for laying ceramics, marble and natural stone. 400x200mm Casalgrande tiles were selected to compliment the existing tiles in the terminal and were installed using Mapei's Kerabond Plus and Isolastic adhesive system. This two-part adhesive system offers a consistently reliable adhesive with over 42 years of unrivalled performance. Superior bond strength, high deformability, low slump and high initial grab are only some of the unique characteristics of this adhesive system that is not only extremely versatile but is also gentle on the environment and conforms to all requirements of the Green Building Council of Australia's Green Star™ programme. Kerabond Plus mixed with Isolastic is particularly suitable for demanding applications such as exterior building facades, shopping centres, airports, swimming pools and aquatic centres and exceeds the requirements of Class S2 (highly deformable) and C2T (cementitious, improved, slip resistant adhesive) according to AS4992.1-2006.

To fast track some of the tiling works in the main walking areas in the airport, the tiling contractor utilised Mapei's Granirapid adhesive system; a two-part rapid setting adhesive that can be set to light foot traffic in only 3 hours and is completely cured in 24 hours. This rapid setting adhesive allows for the tiles to be grouted in around 3 hours and can open up recently tiled areas to light foot traffic in a very short time. This system ensures that work can be completed quickly and confidently and that there is minimal inconvenience to both visitors to the airport as well as staff and contractors working in these areas.

The amenities in the airport were waterproofed using Mapei's Mapegum WPS; a one-part solvent-free waterproofing membrane that can be applied to both walls and floors. Mapei also recommends the use of Mapeband (special waterproofing rubber tape) to be used in conjunction with Mapegum WPS. Mapeband should be installed along the wall and floor edges to ensure complete waterproofing tightness. Special Mapeband corners are available to ensure ease of installation.

Installation of the tiles in the amenities area required the application of Mapei's Keraflex high performance adhesive. Keraflex characteristics allows for tiling on walls with no vertical slip and coupled with an extended open time this adhesive is perfect for the installation of ceramic tiles and dimensionally stable stone material. Keraflex is ideal for internal and external areas and bonds perfectly over waterproofing membranes. Tiles were grouted using Mapei's advanced Keracolor FF grout that contains Mapei's unique DropEffect technology, creating a grout that is water repellent and easy to clean. Keracolor FF grout was also applied to the main tiling areas of the terminal.