Doc. No.

: GENITRPP13A-01

VITRIFIED TILING
Engineering cum Quality assurance manual

Name

Date

Prepared by

Vaibhav Kapoor

12-7-2014

Validated by

Ravi Kumar

14-7-2014

Table of contents
Classification of Tiles
Site storage / site handling
Tools and equipments required for
tiling
Laying of Tiles - Guidelines
Installation procedure
Pre installation
During installation
Post installation
Handover documentation
Common defects and remedies
Best Practices
References and Links

Classification of Tiles
Broadly Tiles Are Classified on the Basis

Capacity of Water Absorption

Abrasion Resistance Characteristics(PEI).

Scratch Hardness (MOH).

Load Bearing Capacity- Modulus of Rupture(MOR),Flexural

Strength, Bending Strength.

Capacity of Water Absorption

Water absorption is a property of ceramic tiles. It depends on the
nature of the tile.
Tiles have the tendency to absorb water. In order to absorb
uniform water & prevent tiles to absorb water from the cement
mortar/adhesives it is essential to immerse the tiles in water
before laying for 5-6 hours.

For Ceramic Tiles

Wall tile
Floor tile

: 10 - 18 %
:36%

For Vitrified Tiles

Porcelain/Glazed Vitrified
: .08% - 3%
Unglazed Vitrified tile
: < 0.08 %

Classification of Tiles

Site storage / Site handling

While ordering;

Study the GFC drawing and BoQ

Estimate the quantity from site measurements
Inform all stakeholders if the variation is beyond +/- 5%
Care should be taken while measuring corners; cut tiles to be
considered as full tiles for estimating quantities
Load wastages as per GFC and site conditions, normally should not
exceed 5%
Update purchase team on staggered delivery and one lot manufacturing
Eg; If we required 1 lakh sqft, we release PO for 1 lakh, everything
gets manufactured in one lot (to avoid variations) but delivery is taken
lot wise
Another alternative is to order floor wise / area wise so that for one
particular area / floor colour variation can be avoided
Site storage facility should be available to store the material

* Check with manufacturer for the size of one batch

Site storage / Site handling

Inspection on receipt of material;

Once tiles are received at site,
following checks are required;
Tiles are of approved make,
size, colour and shade
Any breakages during transit
(corner chipping and cracks)
Quantity of material
Edge guard is provided for all
the boxes

Site storage / Site handling

Site store;
Tiles should be stored on a raised
platform to avoid staining of tiles
Vitrified tiles are heavy, need to be
stored in such a way that it doesnt
have adverse affect on structural slab
due to excess loading (as far as
possible vitrified tiles should be
stored at ground level)
Tiles of sizes more than 500 X 500
should
be
stored
in
vertical
conditions, with not more than 15
boxes in one line
Tiles of smaller sizes can be stored in
horizontal condition, with not more
than 10-12 tile boxes in one pile
As far as possible, re-handling /
shifting of stored tiles should be
avoided
Seek
guidance
/
help
from

Tools and equipments required for tiling

Plumb bob

Laser level

Tile file

Measurement
tape

Tile nippers Floating trowel

Spirit Level

Hoe

Shovel

Wheel barrow

Tools and equipments required on tiling

Tile cutter

Trowel

Mortar mixing
tub

Grinder
machine

Straight edge / Aluminum

bottom

Cutter
machine

Rubber
hammer

Sponge

Tagari

Laying of Floor Tiles: Measure and plan the tile

Layout

For a square or rectangular room: stretch a chalk

line between the centers of two facing walls.

Laying of Floor Tiles

Lay out a row of dry tile along one line from center to
the right wall.

If the last space is less than 1/2 a tile wide, return to the
center and move the first tile 1/2 a tile width to the left.
Mark the new "center point" and strike a new crossing
line at this mark (see Figure 2B)

Laying of Floor Tiles

Work in one of the 4 sections created by the chalk lines.
Starting at the center point, spread mastic over a few
square feet.

Be sure to follow instructions on mastic container.

Laying of Floor Tiles

Leave the row of tile along the walls until last.

These will probably have to be cut.
Do any necessary cutting as you proceed around the
room.

Installation

Pre-installation (Check for site conditions)

Floor tiling
Check mother slab for surface flatness,
levels, cracks and dimensions; report any
major discrepancy to client / PMC
If the slab variation exceeds +/- 10 mm,
take additional approval for increased
thickness of mortar
Surface should be free from concrete
protrusion (concrete lumps on slab)
Check for any water proofing requirements
If its a new concrete surface, it should atleast be cured for 28 days
Check for any reinforcement bars coming out
of the slab / columns (Exposed iron rod result
in
rust
development
which
would
subsequently lead to air bubble formation in
mortar / adhesive)
Recommended to take proper hand over of
the area from the client / PMC with duly
recording all discrepancies

Installation

Pre-installation (Check for site

conditions)
Wall tiling

For wall tiling, check for

verticality of walls and columns
using laser based tools (GLL 380)
Report the deviations beyond +/2 mm
For any major deviations (more
than
+/5
mm)
it
is
recommended to do rendering /
plastering first to bring surface in
plumb
Make sure plastering is cured for
at least 7 days before doing wall
tiling
Recommended to take proper

Installation
Pre-installation

(Check for tiles)

For both wall and floor tiles

Dimensions and rectangularity: Conduct random
sampling (1 in 20 boxes) check for tile dimensions
using measurement tape and vernier calliper
Check for bends in tiles:
Using aluminum box channels / straight edge for
ascertaining the side curvature bends
Pass light through the intersection of tile and channel
to determine the gap / bend / warpage
Check for corner chipping and discoloration

Installation

Pre-installation (Other checks)

Water proofing
Check whether water proofing is required for the area to be
tiled.
Check if water proofing is completed . (Testing done and
checklist signed by client / PMC)
Under floor services work completion
Check for the completion of race way and Conduiting work
Completion of any other under floor work
Quality of adhesive
Check whether adhesive used for tiling is approved by
client / PMC
Quality of cement and sand
Check for the grade of cement (Preferably 43 /53 grade to be
used)
Check for manufacturing date of cement (Cement should not
be more than 90 days old)
Sand should be free from silt and clay (Lab checks for the
quality of sand should be done)

Installation
Quality of grout material
For flooring, use of epoxy grout is advised.
For walls and low traffic areas, use of cementitious
grout is advised.
In any case, specifications given by client / PMC
supersedes above given recommendations; take
necessary approvals before hand from client
Grouting material to be of approved make and shade
For walls, 2 mm spacer is recommended and for floors,
use of 3mm spacers is recommended

Installation

During installation
Floor tiles
Wet the base surface / substrate (Otherwise it would soak
water from the mortar; Also required for proper hydration of
cement mortar)
Provide proper bull marks on the floor and reference lines on
the walls
Check the start point of the tile from the drawing (Start point is
chosen in such as way that all cut tiles are either at the far end
of the entry, So that they not prominently visible or are hidden
below the furniture)
Determine the sizes of cut tiles; Reuse cut tiles in skirting /
flooring in other areas
Mortar mix should be preferably 1:6 (1 part cement mixed with
6 part sand)
Mortar spread should at least be up to arms stretch
Mortar mix should be well compacted before laying the tiles (If
not done properly, hollowness issue will occur)
Soak tiles in water for at least 2 hours to prevent it from

Installation

During installation
Floor tiles
Use cement slurry with cement content 2 kg per sqm slurry spread
Tiling direction is specified on the back surface of tiles; always to follow that
direction marking while doing tiling
Use rubber / wooden hammer to bring tile at exact level (With respect to adjoining
tiles)
Use rubber hammer to check the hollowness below the tiles
If found hollow, take out the tile and provide additional mortar bedding below the
tile
Check the level with spirit level with respect to adjoining tiles
Use appropriate spacers for tiling works
For raceway junction boxes, cutouts should be neatly plugged using cloth or plastic
Make sure the size of cut out in tile matches the exact location and requirement
Do not use pencil for marking on tiles, it may leave a permanent stain on tile
IMP: Masons and civil team should be educated to keep a check on defective tiles
while doing installation, if any deviations or bend is observed while setting out tiles
it should be immediately taken out. These tiles can be used for cut tiles / skirting.
Once the tiling is done, clean the top surface using sponge / cloth
Freshly done tiling should be barricaded for at least 2 days; no traffic / man entry
should be allowed during these 2 days

Installation

During installation
Wall tiles
Wet the base surface / substrate (Otherwise it would soak water
from the mortar; Also required for proper hydration of cement
mortar)
Check the start point of the tile from the drawing (Start point is
chosen in such as way that all cut tiles are either at the far end of
the entry, So that they not prominently visible or are hidden below
the furniture)
For wall tiling, proper curing is to be done for wall plastering before
proceeding with tiling, otherwise plaster would sock water from
cement paste and weaken the bonding with wall tiles)
Soak tiles in water for at least 30 minutes to prevent it from
soaking water from cement paste / mortar
Cement paste composition should be 1:1 (1 part cement and 1 part
water) {depends on tile sizes also}

Installation

During installation
Wall tiles
Use rubber / wooden hammer to bring tile at exact level
(With respect to adjoining tiles)
IMP: Masons and civil team should be educated to keep
a check on defective tiles while doing installation, if any
deviations or bend is observed while setting out tiles it
should be immediately taken out. These tiles can be
used for cut tiles / skirting.
Once the tiling is done, clean the top surface using
sponge / cloth

Application of Adhesives through

Notched Trowel

1/4 inch*1/4 inch(6*6mm.)

3/16 inch*3/16inch (4.5*4.5mm.)

1/4 inch*3/16inch(6*5mm.)

Different size of notched trowel to

meet the requirements of tile laying .

Right selection of Notched trowel saves

consumption of adhesives & mortar
without sacrificing the quality of job.

Made of off steel with high resistance

to abrasion.

Application of Adhesives through

Notched Trowel

The notched trowel forms

grooves on the cement mortar
(as seen in the picture)

These grooves allow the entry

of air beneath the tile.

As a result, it acts like an air

insulation. The noise, which
comes when someone walks
on the tile disappears.

Installation

Post installation
Barricade the area for at least 48 hours. No man entry
should be allowed during this time.
Clean the floor with sponge and a wiper after 2-3 hours
of flooring (Should not clean immediately otherwise it
would affect the tile quality)
If grouting is to be done, it should be taken up during the
end only.
Protect the floor with POP / bubble sheet / rubber sheet

Common complaints and remedies

Jointing

and finishing

Reason

Remedy

Jointing not done

properly

Joints should be
properly filled

Stain by other
trades if left
unprotected

Proper protection
once the work is
finished

Efflorescence (salts
with in substrate or
cement mortar)

Avoid excessive
wetting

Improper grouting

Proper grouting
material should be
used

Spillage of
chemicals

Avoid spillage

Tile surface not

cleaned after
completion of work

Clean the tile

surface after setting
time

Common complaints and remedies

Cracks and chipping

Reason

Remedy

Tiles laid over

cracks

Special treatment
required for cracks

External vibration

Allow movement
joints to avoid
damages due to
external vibration
(design
consideration)

Damage by other
trade after laying if
left unprotected

Proper protection
required

Common complaints and remedies

Uneven surface finish

Reason

Remedy

Tiles with
dimensional defects

Mason to be
educated to check
tile dimensions
before final laying

Premature loading
onto freshly
completed tiling

No traffic
movement for initial
2 days after tile
laying

Insufficient /
excessive tapping of
tiles into position

Use rubber /
wooden hammer or
flat edge to avoid
unevenness

Insufficient leveling
of each tile

Use spirit level for

checking level

Common complaints and remedies

Failure of adhesive / cement mortar joint

Reason

Remedy

Concrete surface /
substrate not
properly cured and
cleaned

Proper surface
preparation to be
done as specified in
installation checklist

Incorrect installation
of tiles; direction not
followed / improper
tapping / delay in
laying after mortar
has dried up

Tiles to be installed
as per installation
checklist

Tile surface not

cleaned properly
before laying

Tile surface to be
cleaned before final
laying

Common complaints and remedies

Hollow sound

Reason

Remedy

Air entrapped or
void inside the
cement mortar
bedding

Ensure proper
workman ship to
avoid void formation
Cement grouting /
nipple grouting
through joints

Separation of
adhesive membrane
between mother slab
and cement mortar

Use sufficient
bonding agents /
cement slurry while
laying tiles

Separation of
adhesive membrane
between cement
mortar and tile

Ensure proper
workmanship to void
non adhesion

Handing over documentation

Handing over document comprises:

All manufacturer's test certificates
Quality checklist duly signed by site engineer and PMC
Snag list duly completed and signed
Lab test reports / 3rd party quality test reports (If any)
Maintenance manual (If any)
Details of attic stock (If any)

Best Practices of Tile Installations

Curing of Tiles before use.
Prewetting of Base Surface of Cement Plaster.
Thorough cleaning of Base Surface.
Study of Tile Box before unpacking of Tiles.
Tile Cutting through Appropriate Tile Cutter.
Hole Making in Tile through Drill Bit.
Tile Installation through Adhesives.
Joint Filling through Grouts.
Application of Adhesives through Notched Trowel & on the
both the surface of tile back & base .

Knowledge Portal
bca.gov.sg
iso.org
bis.org.in
cpwd.gov.in
https://www.youtube.com/results?search_query=how+to+
lay+tiles+on+floor+using+cement+mortar