Bond Strength of Adhesive Mortars to Substrates in ETICS—Comparison of Testing Methods

This study investigates the bond strength of fifteen cement-based adhesive mortars used for expanded polystyrene (EPS) in External Thermal Insulation Composite Systems (ETICS). Field surveys and contractor interviews (170 questionnaires) found that adhesive layer thicknesses in real applications typically range from 15-20 mm and frequently exceed 20 mm, in contrast to the smaller values most often recommended by guidelines and technical instructions. Laboratory testing was conducted using two approaches: the standardized pull-off procedure according to EAD 040083-00-0404 (EAD and EAD' variants) and an in-house pull-off procedure designed to reflect practical conditions of substrate type (concrete slab, silicate block), substrate orientation (horizontal, vertical), and adhesive layer thickness (10 and 20 mm). The results showed that adhesive bond strength is strongly influenced by adhesive layer thickness, substrate type, and substrate orientation. Increasing thickness from 10 mm to 20 mm on concrete substrates typically reduced bond strength by about 65-75%, while vertical orientation lowered adhesion to about half of that obtained in horizontal placement. Silicate substrates exhibited generally lower bond strength but higher variability, occasionally with ratios above unity due to their greater porosity. In some configurations, detachment occurred already during specimen preparation, underlining the variability of performance. The combined effect of increased thickness and vertical orientation on concrete substrates reduced adhesion by about 85% compared to the 10 mm horizontal baseline, highlighting the severity of unfavorable application conditions, whereas on silicate blocks, the effect was weaker but accompanied by large variability. The findings indicate that adhesive layer thickness has a stronger impact on bond strength than orientation and that substrate properties play an important role. The study provides a comparative perspective on current and alternative testing approaches, revealing significant differences in the results. The author's testing method makes it possible to account for, in laboratory conditions, primarily the geometric shape and orientation of samples that are close to the actual form of adhesive mortar application in real insulation installations. This allows for the assessment of the properties of mortars and substrates that were not exposed under the conditions of current testing methods. The above provides a basis for further discussion on the inclusion of realistic application conditions in the evaluation of adhesive mortars used for bonding thermal insulation in ETICS, and for the validation assessment of an additional testing method, which is currently of an experimental nature.