The Art of Professional Industrial Flooring

8/6/2019 The Art of Professional Industrial Flooring

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Submitted to - Eng. Hany //////// Eng Alex

Place : Corvertina Chocolate Factory , Abhoor, Cairo , Egypt.

Prepared by - Visakh john Thomas ///// Showky Abdul Haleem


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Contents

1. Mortar Preparation2. Floor Preparation3. Screed4. Tile Laying Process5. Vibration process6. Grouting7. Common Working Tools8. Labors9. Cost10. Notes

Main Tools List

1. Mortar Mixing Machine2. Vibrator3. Laser Level Equipment4. Cleaning Machine5. Epoxy Mixer6. Manual Tile Cutter


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1. Mortar Preparation

Fourty two shovels of sand (0.15 m 3 ), one packet cement (50 Kg ) and 25 -28 liters of chemical mixed water .

Chemical mixed water is made of 200 liters of water and 3liters of Retardol 25 , make Sika.( Reduce setting time and

increase strength)

Prepare mortar in a mixing machine Mixing time will be between 1 -2 minutes.

Practically check the mortar with hand for best results.


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2. Floor Preparation

Always prefer a rough concrete surface with required slope.

Prepare an area of around 50 sq.m at one time.

Over this concrete surface first apply water to make it wet.


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Then spread one or two cart of mortar and one packet ofcement over the wet surface to make a slurry that will helpthe screed to adhere the concrete surface more firmly.

3.

Screed First make reference level for the screed at different areas

with respect to the required slope with mortar using a laserlevel equipment .


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For the free flow of work make ramps between the highestlevel and lowest level with spacing of 2 meters ( more than 2meters is good for highly skilled workers )


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Then fill the space in between the ramp with mortar.


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Compact and level it properly with workers shoes , troweland aluminum bar.


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Laser level setting instrument

Trowel Aluminum hollow Bars

Mercury level


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4. Tile Laying

Fix the starting point and then make straight lines along xand y axis with plastic line and aluminum hollow bar.


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Spread cement powder on the top of the screed using anormal cleaning brush.

Ensure the tile needed for laying is kept nearer to the area.


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Wear special shoes while walking over the screed and laidtiles.


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Lay the tiles one by one just behind the previous one.


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Normally tiles comes in two types first quality ( 22 euro) andsecond quality ( 10 euro).

While installing first quality tiles you will get the all thelines in straight . So later no adjustments is needed.


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In case of second quality tiles along the longitudinaldirection the straight lines will be adjusted at the middleand at the end using a plastic line tied between first tile andlast tile. In the lateral direction normally they will not keepthe lines straight.

If in the corrected line the gap is more reduce it by adjustingthe side by tiles.

After finishing one area check the tiles are laid properly. Cut pieces are done by using a manual tile cutter and remove

the extra part by chipping it with a small hammer.

After finishing an area ( eg. 25 sq.m) the excess mortar andthe end tiles should be removed and cleaned properly.


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5. Vibration Process

Apply water on the tile laid surface with hose or bucket .

Remove on tile and check the bottom part is wet ( just presson the screed with your thump and check the impression).

If it is not properly wet apply water again. Start vibration from one end and do an area of 25 sq.m at

one time.


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Vibrate twice over the same tile by moving forward andbackward.

Vibration m/c has three speed ( use the third one).

During vibration remove two or three tiles and check thescreed is adhered to the tile surface properly. If the tile is not adhered to the screed properly apply wateragain and do the same the procedure.

Later check all the tiles are in same level and if not by usinga rubber hammer correct it.

6. Grouting


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Grouting should be done after one week only.. Keep the area clean by not allowing persons to walk above it. Before do grouting clean the tile surface properly using a

brush.

Spread silica sand on the top of the tile surface with a wiper.

Wipe it twice over the tiled surface to fill the tile gaps . The silica sand is the body for the epoxy . Otherwise without

silica sand pin holes will appear after get dry.

Clean the tile surface with a brush to remove the excesssilica sand. Mix the epoxy ( one bucket 6.5 liters and another bucket 3

liters) with a mixing rod.

Pour it on the tile surface .


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Again do the same process one more time with anothercleaning machine to get the tile surface free from epoxy.

The time limit to complete the whole process of grouting aftermixing the epoxy is 45 minutes.

6 A. Tools required to do Grouting

Cleaning Equipment Epoxy Mixer


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Cleaning Equipment Brush

7. Common Working Tools needed for the whole process Cleaning Brush Wiper Rubber Hammer Plastic Line Chipping Hammer ( small) Shovel Cart

8. Labors Needed 5 professional + 3 helpers9. Cost - 25 euro for Installation

Note:

A. Professional Workers were Croatians.B. helpers from EgyptC. No expansion joint work . Only information is keep plastic like

material 2 centimeter deep and 1 cm thick at the centre of two drainline.

D. Dont pour water on the t iles in between fixation and grouting.E. The main two criteria in this tiling is one proper mixing , compaction

and next is keep the screed wet until vibration completes.F. Every day after work finishes ensure that the extra mortar is removed

and end tiles are cleaned properly.G. Skirtings are fixed with this same mortar only difference is add water

a little more. No vibration just use hammer and mercury level.


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Finished Surface

Thank You

Documents

The Art of Professional Industrial Flooring