System And Method Of Installation Porphyry Stone
Approved porphyry stone “mosaic or random tiles” tiles are laid, in random pattern or orderly pattern, over a bedding mortar above a concrete slab or a compacted Substrate.
Mortar joints in ‘Mosaic or Random tiles, Cobblestones and Split Tiles’ shall be to a maximum of 25mm and a minimum of 10mm to have a uniform pattern, the preferred finished level of the grouting is 3/5mm below the finished level of the tiles.
Grouting of Sawn Tiles shall be of a continuous 3mm joint (or other Specified but not less the 3mm).
Paving which does not comply with these tolerances will be rejected by the Superintendent and re-laid in accordance with the specification at the Contractor’s expense.
- Road paving (Light / Heavy Traffic)
- Footpaths/Boardwalks/Shopping Precincts
- Permeable Urban Tree surrounds
- High Traffic Public Pedestrian Areas
- Demarking areas / Pedestrian crossings
- Anti-rollerblade / Skateboard areas
- Versatility on intricate pattern design
- Pool surrounds – Garden edges – Courtyards
- Urban Infrastructure
- Speed Warning Humps / school crossings
- Landscaping Roundabouts / Intersections
- Unique Dimensional Slabs
- Entertaining Areas / Bench tops / Stairs
- Fireplace surrounds – Natural and exfoliated
- Feature Retaining Walls / Cladding
PREFERRED FINISH FLAT TOLERANCE
In general (ESPECIALLY WITH SAWN TILES) a flat tolerance of + – 3mm measured in all 3 face directions, i.e., lengthwise, across face and diagonally depending on level and water falls Contractor is to ensure that trip edges are not created by uneven pavers. Any trip edges in excess of 3mm will be rejected by Superintendent.
Stone is to be free of structural faults, such as vents or fissures, which may cause eventual cracking or layering in paving, copings and boulders. Stone shall also be free from Dirt, Clay or other materials.
The Contractor is to procure the stone in close liaison with the Superintendent, at the time of contract acceptance. Stone shall be delivered on Pallets Weight 1.2 Ton in timber plastic vacuum wrapped.
The paving will be subject to shop drawings.
A detailed Method Statement is to be submitted for approval prior to supply/installation.
The method statement is to include but not be limited to ordering, selection from source, transport, cutting, laying / installing, co-ordination with other services/trades and materials, cleaning down, and maintenance recommendations.
A 4 square meters sample of paving and a 3m x 600mm high sample of wall cladding shall be constructed for approval. Sample by standard to include usually medium grey coloured grout as per Specification.
If approved, the samples may be incorporated into the work. Otherwise the sample is to be demolished and removed from site. Once approved the sample will set the standards for all other work
The stone mason is to have a minimum of 10 years experience in all aspects of this system.
Submit details to Superintendent for approval.
- Relevant projects • Key personnel • Referees • Methodology
BEDDING AND FIXATIVE MATERIALS ; Materials for installation of stonework shall be CT Products Stone Set Adhesive, water and coarse graded washed sand and Portland Cement Type G.P.
SAND ; Coarse graded washed sand
GROUTING ; Grouting can be carried out using Portland Cement Type G.P. and fine washed sand conforming to the
ADDITIVES ; Mortar additives shall be non-toxic, non-flammable and non-hazardous during storage, mixing, application and when cured.
DELIVERY; Materials shall be delivered to the job site in the original containers with the manufacturers identification on each package.
HANDLING & STORAGE OF MATERIALS
Handle and store stone in a manner to avoid chipping, breakage or the intrusion of foreign matter.
Handle, store, mix and apply proprietary setting and grouting materials in compliance with the manufacturers instructions. Take precautions to protect the mortar admixtures from freezing or heating excessively.
SLURRY BEDDING ; Thick bed slurry shall consist of 1 kg. Of Type G.P. cement x 1 litre of potable water + Laticrete (or similar as per specifications) adjusting liquid to obtain proper creamy consistency.
SPREAD/BRUSH THE SLURRY ON THE CONCRETE SLAB AFTER WETTING WITH CLEAN WATER
BEDDING MORTAR MIX ; Thick bed mortar mix shall consist of local river fine washed sand (or as specified) and Type G.P. cement in a 3:1 ratio and add 10 kgs of Laticrete (or similar ) per 3.5 cub.ft. standard mixer batch.
SPREAD THE BEDDING MORTAR ON THE CONCRETE SLAB (PREVIOUSLY BRUSHED WITH SLURRY BEDDING) IN THE REQUIRED THICKNESS TO ALLOW THE TILE TO BE LAID FIRMLY IN POSITION WITH A WHACKING ACTION USING A STONEMASON’S MALLET.
BACK TILE BATTER MIX ; SAME AS PER SLURRY BEDDING – Thick bed slurry shall consist of 1 kg. Of Type G.P. cement x 1 litre of potable water + Laticrete (or similar as per specifications) adjusting liquid to obtain proper creamy consistency.
SPREAD/BRUSH AT THE BACK OF EACH TILE EVENLY PRIOR TO BE LAID ON THE BEDDING MORTAR
GROUT MIX ; Grout mix shall consist of local river washed fine sand as specified and Type G.P. cement in a 2:1 ratio mixed with potable water and in a ratio of 1:2 to obtain proper consistency + Laticrete (or similar as per specifications).
Grout to be coloured (If specified) with natural pigments to achieve the desired colour.
Contractor to prepare sample for the approval of the Superintendent prior to commencement of paving.
SWEEP/BROOM THE SLURRY GROUT MIX ON THE TILES DEEP WITHIN THE JOINTS BETWEEN TILES
(SLOWLY FOLLOW THE DIRECTION OF THE PATTERN WHILE SPREADING THE GROUT ON THE TILES)
IMPORTANT: CLEAN THE TILES WITH APPROPRIATE SPONGES AND FREQUENTLY CHANGE WATER
PREPARATION OF BACKGROUND MATERIALS
Prior to commencing installation examine areas to be covered.
Existing conditions or surface contamination requiring correction before work commences.
Surface to be covered shall be cleaned to remove soil, mortar, grease, oils and sealants.
Dry or dust concrete or masonry surfaces shall be wet down or washed and excess water removed just prior to the application of the stonework.
MACHINE MIXING ; Mixer shall be a rotating blade type mortar mixer. (Allows a semi dry product and keeps the mortar aerated and soft) Place liquid into mixer, start machine and add dry material.
Mix only long enough to thoroughly wet out the batch.
Do not over mix. Stop mixer and dump mortar from mixer promptly.
Is preferred to clean the mixer with water promptly after each batch.
Apply slurry mix as specified to the clean and dry base surface using a bucket and hard broom ensuring complete coverage of the area to be laid.
Apply mortar thick bed mix as specified to required thickness, spreading to grade, tamped and float finished with a steel or wooden float to the area to be laid.
Once mortar thick bed is prepared, and prior to placing stones, brush the back of each tile with slurry.
Note: This will add adhesion of stone to the mortar bed. With the mortar bed ready for laying, select stone to suit required pattern, place on mortar bed and hand tamp each piece firmly into the bed, ensuring finished levels are correct.
Only an area that can be completed in 30 – 40 minutes at any one time should be prepared.
GROUTING ; Areas to be grouted shall be given 24 hours to cure but no more than 72 hours prior to grouting commencing.
Apply slurry mix grout as specified to stone beds using sponges and trowels.
Spread grout mix with trowel over area to be grouted, then using circular motions with the sponge wipe the group mix into all joints, ensuring complete coverage and removal of any air pockets in joints.
Excess material shall be sponged off or Cleaned with a High Pressure Cleaner.
Contractor to ensure grout surface widths do not exceed maximum tolerances specified.
Ensure all adjoining finished surfaces are protected from staining and that any spillage is cleaned immediately.
Only as much grout as can be completed within 30 – 40 minutes shall be attempted.
KEY JOINTS AND SEALANTS ; If required, Joints in surrounding precast paving shall be carried through stonework as shown on the Engineer’s drawings.
Where key joints occur under stonework the stone shall be sawn full depth exactly 24 hours after laying to allow the key joint to be projected through the stone.
Foam Expansion Joints shall be installed in accordance with details Drawings and manufactures recommendations.
PROTECTION ; Protect surfaces from damage resulting from the provision, use and removal of constructional plant, including scaffolding, hoardings, gantries, hoisting facilities and the like.
Isolate points of contact or potential contact. Damaged units prior to or after installation, will be rectified / replaced at the Contractor’s expense prior to the date of practical completion.
NOTE: PORPHYRY STONE PRODUCTS DO NOT NEED TO BE SEALED