Installation of Marble and Granite Tiles on floor, stairs, walls and counters

This method statement covers the detailed procedure to be followed for Supply & Installation of Marble and Granite tiles on floor, stairs, walls and counters and other areas as per the schedule of finishes for the project.

MARBLE INSTALLATION:

Marble Delivery: Site Engineer shall ensure that all materials shall be delivered to site comply with approved samples and shall be assigned at temporary storage locations at Site according to its fixing location.

The fixing location of each individual stone panel shall be defined by level number related identification marking to ensure compliance to the approved shop drawing and traceability.

Stone panels shall be delivered to site on a Floor by Floor basis. All material and fixing material shall be off loaded to temporary loading area.

Material shall be handled with care in order to avoid any damage. The material shall be unloaded to the working area, if the site condition allows. The Stone panel shall be placed evenly on the floor slab and ensure the weight must not exceed the loading of weight of the slab.

Each Panel, tile, to be checked against the following prior to installation:

• Location of its temporary storage area
• Within the control range
• Within the fabrication tolerances.
• Free from cracks, broken corner, chipped arises, scratches or defects.
• Color matching

Pre-Installation: Site Condition Checking And Setting Out 

• Site Engineer shall check site condition to ensure readiness for tile fixing. Main contractor shall sign off clearance to lay tile for each floor separately.
• Store approved marble tiles near each work area.
• All other work must be finalized prior to marble installation.
• Check the surfaces indicated to receive stone flooring for compliance with requirements.
• Clean concrete substrates to remove dirt, dust, debris and loose particles that could affect mortar bond.
• Clean dirty or stained stone surface using clean water.
• Dry-lay marble designated to each level. Submit inspection request for marble approval prior to final fixing at required level.
• Apply water proof material to back of marble in two coats. Allow 1 hour pace between coats.

Flooring: Preparation of the Area 

• Engineer shall check site condition to ensure readiness for tile fixing.
• Approved marble tiles will be handling near each working area.
• Check the layout shop drawings related grid lines & levels are given.
• Clean concrete substrates by removing dirt, dust, debris and loose particles that could affect mortar bond.
• Clean dirty or stained stone surface using clean water.
• Dry-lay marble designated to each level.
• MEP clearance or any other work.
• Mortar/ bonding material to be ready at required area.

Conventional Floor Tile Fixing

Prepare bedding layer as follows:

Portland Cement: 50 kg

Sand: 150 kg

Clean Water: 10 liter

Bedding shall be semi dry when spread to floor.

Prepare slurry as follows:

Portland Cement: 25 kg

Clean Water: 5 liter

Spread Slurry Mix evenly to bedding layer to the desired thickness ( ranging from 40 mm to 70 mm)

Provide reference lines for setting out point and finished floor level by fish strings etc.

Working area will be fenced off for installation and construction.  Traffic is strictly prohibited.

Mix the sand cement mortar with clean water using mobile rotary mixer set nearby laying area.

Build up the semi dry mortar to the required thickness 30 mm as per approved shop drawings.

Level the semi dry mix using a flat trowel.

After compaction, check stone surface against reference lines & adjacent finished floor by level and finger touch.

In case there is a difference compared with the reference lines or adjacent finished floor, remove the tile.

Remove or refill the semi-dry mortar until the correct mortar level is achieved.

Apply Slurry to the compacted mortar surface (prepared as described)

Make sure that the slurry bond is fully covering the compacted mortar surface.

Lay tile again and repeat compaction by means of soft hammer. Beat the tile in order to obtain a flat and leveled surface.

Traffic to be prohibited from installed stone floor for a minimum of 48 hours.

Clean off all joints to depth required to receive the approved grout.

Mix the approved grout powder with water according to the manufacturer instruction to obtain a homogenous paste.

Apply the grout with a rubber trowel to fill the joints completely.

Wait for 10-20 minutes and clean off excess grout with slightly damped sponge.

Allow the grout to set for at least 24 hours before allowing foot traffic.

Grouting Of Stonework Joints 

• Check and ensure that the mortar bed has set. Clean off all loose toppings or any substances that may reduce or inhibited the grout to the stonework joints.
• Add 10 Kg of approved grout product fine grain to 2.1 – 2.3 liters of clean water stir until a homogeneous paste. Leave to rest for 2 to 3 minutes and remix before.
• Apply the grout with a rubber trowel to fill the joints completely.
• Wait for 10-20 minutes and clean off excess grout slightly damped sponge.
• For stone flooring; allow the grout to set for at least 24 hours before allowing foot trafficking.

Temporary Protection 

• Floors inspected and approved shall be protected as follows:
• Clean marble with Wiper using clean water
• Apply Polypropylene board sheets to marble surface for foot traffic protection; more than the foot traffic, the main contractor shall be responsible for the protection.

Wall Cladding:

Each Panel, tile, to be checked against the following prior to installation:

• Location of its temporary storage area.
• Within the control range
• Within the fabrication tolerances.
• Free from cracks, broken corner, chipped arises, scratches or defects.

Pre-Installation: Site Condition Checking and Setting Out

• Site Engineer shall check site condition to ensure readiness for tile fixing. Main contractor shall sign off clearance to lay tile for each floor separately.
• Store approved marble tiles near each work area.
• All plumbing, electrical, etc works must be finalized prior to marble installation.
• Check the surfaces indicated to receive stone cladding for compliance with requirements.
• Clean concrete substrates to remove dirt, dust, debris and loose particles that could affect mortar bond.
• Clean dirty or stained stone surface using clean water.
• Locate Starting point & check for horizontality & Verticality of walls

Mechanical Fixing (Dry Fixing):

Area to received stone shall be checked.

Panels shall be drilled to allow for pin and holes will be parallel to face of tile and centered from the edge. Location of hole shall be as per shop drawings.

Tiles shifted to required elevation should rest on wood to avoid breakage.

Tiles shall be lifted by labor to required area.

Prior to fixing of tiles, wooden templates will be fixed at lower level of tiles. Template shall hold temporarily tiles at lower layer.

Bracket location shall be marked and hole for Anchor will be drilled to required depth.

Drilled hole in concrete/Steel shall be cleaned from dust using Air blower.

Drilled holes in stone shall be partially filled with approved stone adhesive.

Already approved tiles shall be set, plumb, square, true and in plain with uniform joint and in accordance with shop drawing.

Anchor bracket shall be fastened tightly

The Alignment face for panels shall be the outside face

Under no circumstances any panel butt directly against and/or bear directly upon another unit.

Wedges shall be used for temporary holding of tile shall be removed after complete fixing of tile.

Joints to cladding shall be as indicated on shop drawing.

Installed stone shall be kept clean as work progress

Prior to handing over, all work shall be cleaned using proper cleaning products.

Temporary Protection: 

Floors inspected and approved shall be protected as follows:

• Clean marble with Wiper using clean water
• Apply Polythene sheets to marble surface
• Apply 3cm thick chip-board sheet above Polythene sheets.
• Seal chip-board joints with 2” masking tape.

Final Polishing: 

• All floors shall be polished to achieve approved sample / Mockup.
• Inspection request shall be submitted for handing over of works, once works are approved
• Then no further protection will be applied

Control Joints: Control joints, as shown on drawing will be applied around floor perimeter at walls & columns, as follows:

• As per the drawing indication
• Application as per Manufacturer’s instruction