Zhenhao Stone Company is a professional stone producer and exporter from China. With over 20 years of production and export experience, our main products are exported to countries and regions such as Japan, Europe, Australia, the Middle East, South Africa, Mexico, etc.This article is applicable to marble, granite, and mosaic marble flooring projects in high-end public buildings.
( Note: if interested in our products, please don't hesitate to contact diana at diana@zhenhaostone.com, or add on wechat diana_peng1984 , we wish to have double wins cooperation with you. )
1. Material requirements
(1) The varieties, specifications, and quality of marble tiles, granite tiles, and Mosaic marble (all finished products processed by our factory) should comply with the design and construction specifications.
(2) Cement: Ordinary Portland cement with a grade of 325 or above, and prepare an appropriate amount of white cement for joint cleaning.
(3) Sand: Medium sand or coarse sand
(4) Mineral pigments (for seam cleaning), wax, oxalic acid.
2. Main equipment
Trolley, shovel, guiding rule, mortar kettle, bucket, watering can, iron trowel, wood trowel, ink bucket, steel tape, nylon wire
Rubber hammer (or wooden hammer), iron level ruler, curved square ruler, steel axe, alloy steel flat chisel, bench drill, alloy steel drill bit, broom, Sand, wheel, grinding machine, wire brush.
3. Homework conditions
(1) After entering the site, marble slabs (granite slabs) should be stacked indoors, standing side by side, with wooden padding underneath. And carefully check whether the variety, specifications, quantity, quality, etc. meet the design requirements. Cracks, missing edges and corners are not allowed to be used.
(2) Set up a processing shed, install the bench drill and grinding wheel saw, and connect the water and power supply. The board that needs to be cut and drilled should be processed before installation. Some customers require our factory to drill holes before shipping.
(3) Indoor plastering, floor cushion, water and electricity equipment pipelines, etc. have all been completed.
(4) Draw a 50cm horizontal line on the walls around the room.
(5) Before construction, a detailed drawing of the marble floor should be drawn (especially for mosaic marble, which should be pre assembled and numbered according to the drawing).
4. Do you know the Operation process for Marble or Granite Flooring Tiles?
Marble and granite flooring process:
Preparation work → snap line → trial assembly → numbering → brushing cement paste bonding layer → laying mortar → laying marble tiles (or granite tiles) → filling and wiping joints → waxing
(1) Preparation work:
1) Familiar with drawings: Based on construction drawings and processing orders, familiarize oneself with the dimensions and methods of each part, and clarify the relationships between openings, corners, and other parts.
2. Base treatment: Clean the debris on the ground cushion layer, brush off the mortar bonded to the cushion layer with a wire brush, and clean it up.
(2) Trial assembly:
Before formal installation, the marble (or granite) tiles in each room should be trial assembled according to the pattern, color, and texture. After trial assembly, they should be numbered and arranged in two directions, and then neatly arranged according to the numbering. (Note: Generally, we have already arranged the boards in the factory and labeled the stone numbers for easy construction at the work site.)
(3) Draw mutually perpendicular control cross lines in the main parts of the room to check and control the position of marble tiles. The cross lines can be drawn on the concrete cushion layer and led to the bottom of the wall. And based on the wall surface elevation line, mark a horizontal line on the wall to match the floor elevation of the corridor.
(4) Lay two strips of dry sand in two mutually perpendicular directions in the room, with a width greater than the slab and a thickness not less than 3cm. Based on the trial assembly results and construction drawings, combined with the room dimensions, arrange the marble (or granite) slabs in order to check the gaps between the slabs and verify the relative positions of the slabs with walls, columns, openings, and other parts.
(5) Brush cement paste bonding layer:
Before laying the mortar, clean the concrete cushion layer again (including dry sand and marble blocks used for wiping), then use a spray can to sprinkle water to moisten it, and brush a layer of plain cement paste (with a water cement ratio of about 0.5, and lay the mortar as it is brushed).
(6) Laying mortar:
Based on the horizontal line, determine the thickness of the ground leveling layer, draw a cross control line, and lay the leveling layer cement mortar (the leveling layer generally uses a 1:3 dry hard cement mortar, and the degree of dryness is suitable for hand pinching into a ball without loosening). The mortar is spread from the inside towards the entrance. After laying, use a large bar to smooth it out, and then use a trowel to compact and level it. The thickness of the leveling layer should be 3-4mm higher than the horizontal line of the marble surface elevation
(7) Laying marble blocks (or granite blocks): Generally, the room should be laid along the control line from the inside to the outside, starting from the side away from the door, laying in sequence according to the trial assembly number, and gradually retreating to the door. Before laying, the board should be pre soaked and dried in the shade for later use. Trial laying should be carried out first, and the longitudinal and transverse joints should be aligned. The wooden pad should be struck with a rubber hammer (not directly striking the marble slab with a rubber hammer or wooden hammer). After compacting the mortar to the laying height, the marble (or granite) should be lifted up and moved aside to check whether the surface of the mortar matches the board. If any voids are found, mortar should be used to fill them. Then, formal laying should be carried out. First, pour a layer of plain cement mortar bonding layer with a water cement ratio of 0.5 on the cement mortar leveling layer, and then lay the marble slab (or granite). When placing it, all four corners should fall down at the same time. Use a rubber hammer or wooden hammer to lightly tap the wooden pad and level it with a molten iron ruler according to the horizontal line. Lay the first piece in sequence towards both sides and backward direction. The joints between marble (or granite) slabs should be tight and generally not leave any gaps.
(8) Sealing: Grouting and sealing should be carried out 1-2 days and nights after paving. Select the same color based on the marble (or granite) color, mix mineral pigments and cement evenly to form a 1:1 dilute cement slurry, slowly pour it into the gaps between the marble (or granite) blocks with a mortar pot (in several stages), and use a long scraper to feed the flowing cement slurry into the gaps. After grouting for 1-2 hours, use a cotton ball dipped in the original dilute cement slurry to wipe the joints, level them with the surface of the board, and wipe the cement slurry off the surface of the board at the same time. Then the surface layer is covered for protection.
(9) When each process is completed, waxing can be done to achieve smoothness and cleanliness. The waxing method is detailed in the freshly made terrazzo floor.
(10) Winter construction: The temperature of raw materials and operating environment shall not be lower than 5 ℃, frozen sand blocks shall not be used, and there shall be no freezing phenomenon on the surface of stone slabs. Construction is not allowed without heating and insulation measures indoors.
(11) Process flow of pasting marble skirting:
1. Paste method:
Find the elevation horizontal line and determine the wall thickness → Cement mortar base → Paste marble skirting board → Wipe joints → Waxing
A. Determine the thickness of the skirting board out of the wall based on the thickness of the main wall plaster hanging line, generally 8-10mm.
B. Use a 1:3 cement mortar base to level and scratch the surface layer.
C. After the leveling layer mortar has dried and hardened, pull the horizontal line on the upper opening of the skirting board, and place the back of the wet and dry marble skirting board,
After scraping a layer of 2-3mm thick plain cement slurry (preferably adding about 10% 107 glue), stick it onto the bottom ash and use a wooden hammer to compact it. Sweep it straight according to the horizontal line.
D. After 24 hours, use the same colored cement slurry to wipe the joints and clean the remaining slurry.
E. Waxing simultaneously with marble flooring.
2. Grouting method:
Find the elevation horizontal line and determine the wall thickness → pull the horizontal line → install the skirting board → pour cement mortar → wipe the joints → wax
A. Determine the thickness of the skirting board out of the wall based on the thickness of the main wall plaster hanging line, generally 8-10mm.
B. Install a kickboard at each end of the wall, with its upper height within the same horizontal line and consistent thickness outside the wall. Then pull a line along the top of the two skirting boards and install them one by one in order, checking the levelness and verticality of the skirting boards at any time. Stabilize the space between adjacent blocks and between the skirting board and the ground or wall with plaster.
C. Fill with 1:2 dilute cement mortar and wipe off any spilled mortar at any time. After the cement mortar is fully set, remove the gypsum.
D. Dip a cotton ball into a thin cement slurry of the same color as the marble skirting board to wipe the joints.
E. The surface layer of the skirting board should be waxed together with the ground, using the same method as the terrazzo floor.
F. The seams between the kickboards should be aligned with the marble floor and embedded.
(12) Process flow of crushing and assembling marble surface layer:
Select fragmented marble → snap line trial assembly → base treatment, sweeping cement paste, laying mortar and leveling layer → laying fragmented marble → grouting → polishing and waxing
1). Select fragmented marble according to the color and specifications required by the design, and remove marble with cracks.
2). According to the design requirements of the pattern, combined with the room size, draw lines on the base layer and find the elevation of the surface layer, and then conduct trial assembly, determine the size of the gap.
3). After cleaning the base layer, sprinkle water to moisten it and brush with cement paste.
4). Lay a leveling layer of mortar with a horizontal line, using a 1:3 ratio of dry hard cement mortar (which can be kneaded by hand and easily dispersed when shaken). After laying, use a large bar to scrape it flat and use a trowel to smooth it out.
5). Lay fragmented marble according to the pattern and trial joints, using the same method as marble flooring.
6). After laying for 1-2 days and nights, grouting should be carried out. According to the design requirements, when pouring cement mortar, the thickness should be level with the surface of the crushed marble, and the surface should be smoothed and pressed. If cement stone slurry needs to be poured, it should be 2mm thicker than the crushed marble. Watering for maintenance shall not be less than 7 days.
7). If cement mortar is used to fill the joints, it should be polished and waxed four times after curing, and the waxing operation process should be the same as the water grinding ground method for each time.
5. Quality standards
(1) Guarantee project:
The variety, specifications, and quality of marble and marble fragments must meet the design requirements, and the bonding between the surface layer and the base layer must be firm without hollowing (delamination).
(2) Basic project:
1) The surface of marble (or granite) is clean, with clear patterns, bright and smooth, consistent color, uniform joints, straight edges, and no cracks, missing corners, or other defects in the panels. Crushed marble has a harmonious color, suitable gaps, consistent polishing, and no cracks, potholes, or scratches.
2) The slope of the floor drain meets the design requirements, does not overflow or accumulate water, and the joint with the floor drain is tight and firm, without leakage.
3) The surface of the kickboard is clean, the joints are flat and uniform, the height is consistent, the bonding is firm, and the thickness of the wall is suitable. The material and size of the edging meet the design requirements and construction specifications, and the corners are neat and smooth.
(3) Allowable deviation items: see Table 4-21.
Table 4-21 Allowable Deviation for Marble (or Granite) and Mosaic Marble
| Item number | Project | Allowable deviation (mm) | Testing method | |
| Marble | Mosaic Marble | |||
| 1 | Surface flatness | 1 | 3 | Check with a 2m ruler and a wedge-shaped feeler gauge |
| 2 | Seam grid straight | 2 | - | Pull a 5m line, if it is less than 5m, pull a straight line and check with a ruler |
| 3 | Check the height difference of the seam | 0.5 | - | A wedge-shaped plug gauge |
| 4 | The skirting line has a straight opening | 1 | - | Pull a 5m line, if it is less than 5m, pull a straight line and check with a ruler |
| 5 | The width between tiles should not exceed | 1 | - | Use Ruler for inspection |
6. Finished product protection
(1) Store marble slabs without rain, water damage, or prolonged exposure to sunlight. Generally, plates are placed vertically, with smooth surfaces facing each other. The back of the board should be cushioned with pine strips, and wooden blocks should be placed underneath the board. Soft rubber should be placed between the blocks. When transporting within the construction site, the above requirements should also be followed.
(2) When transporting marble (or granite) slabs, cement mortar, measures should be taken to prevent collisions with already completed walls, doorways, etc. When laying the floor water, prevent soaking and contaminating the floors and walls of other rooms.
(3) Trial assembly should be carried out in a flat room or operating shed. Personnel responsible for adjusting the plates should wear clean soft soled shoes when handling the plates.
(4) During the process of laying marble (or granite) slabs and crushing marble slabs, operators should wipe them clean as they are laid. The marble surface should be wiped clean with a soft bristled brush and dry cloth.
(5) The rooms with newly laid marble (or granite) slabs should be temporarily enclosed. When operators and inspectors step on newly laid marble slabs, they should wear soft soled shoes and lightly step on the slabs.
(6) When walking on marble (or granite) or crushed marble floors, the compressive strength of the leveling layer mortar shall not be less than 1.2Mpa.
(7) After the completion of marble (or granite) flooring or crushed marble flooring, the room shall be enclosed or its surface shall be covered for protection.
7. Quality issues to be noted
(1) Hollow surface and base layer:
Due to incomplete cleaning or insufficient watering of the concrete cushion layer. Uneven application of cement paste or prolonged drying after application. Add water to the mortar used for leveling at will. Factors such as lack of immersion and moisture in marble slabs can easily cause hollowing. Therefore, it is necessary to strictly follow the operation process requirements that the base must be cleaned thoroughly, and the leveling layer mortar should be dry and hard. A layer of plain cement slurry should be applied as it is laid. Marble (or granite) slabs must be soaked in water and moistened before laying.
(2) At the end, there are large and small heads:
when laying, the operator did not pull through the line or different operators did not grasp the size difference between the blocks when laying in the same row. So before laying, it is necessary to pull through the line, and the operator should follow the line to lay. After each line is laid, immediately pull through the line to check whether the gap is straight and avoid the phenomenon of large and small heads.
(3) Uneven seams and uneven width of seams:
The main reason is that the panels themselves have defects such as thickness, width, angle deviation, and warping, which were not strictly selected in advance, and the horizontal elevation lines in the room are not uniform. Failure to strictly pull through the lines during paving can easily result in defects such as uneven seams and uneven joints. Therefore, it is necessary to strictly select the blocks in advance, and any blocks that are warped, arched, or have uneven width should be removed and not used. After laying the standard blocks, they should be laid in sequence on both sides and in the backward direction, and a level ruler should be used at all times. Align with the ruler, the seam must be pulled through without any deviation. The elevation line in the room should be introduced by a dedicated person, and the elevation of each room and hallway must be consistent.
(4) Activity of stone slabs at the entrance:
The stone slabs at the entrance were not timely connected to the adjacent ground during paving. In terms of process arrangement, room floors other than marble (or granite) floors should be completed first. The marble slab at the entrance is laid simultaneously with the ground.
(5) The thickness of the skirting board outside the wall is inconsistent:
when tiling the skirting board, it is necessary to control it by pulling a line.
