TILE INSTALLATION: CONCRETE DRY PACK METHOD

June 14, 2016
MABUHAY!
I did a weekend construction project of installing tiles in my garage. Tiles are commonly installed in 2 ways. The most common way is the THIN-SET INSTALLATION wherein the tilesetter mason will apply a 6mm to 10mm tile adhesive using a notched trowel. This is applicable for flooring with concrete topping and the finished level is already established. Another method is the DRY PACK INSTALLATION. This is applicable for the finished floor level of more than 25mm thickness of mortar grout.

TILE INSTALLATION SHOP DRAWING

Careful study must be done to determine the final layout of the tiles. First to consider is the tile setting point (TSP) which is the first tile to be installed by the tile setter mason. The TSP will affect the rest of the tile layout especially if your tiles have floor pattern design. For this particular project, I added a raised floor level with a floor drain to place my washing machine. I also place the exact location of the hose bibb/faucet. This drawing will aid you in counting how many tiles you will purchase. Make sure to add 3 to 5% additional pieces to your quantity for breakage and attic stock. For the dry-mix mortar grout, the ratio is 1 bag of Portland Cement (40 kg) to 3 cubic feet of fine sand aggregates.

The tile installation shop drawing

MATERIALS

For this particular project, the materials to be used are:

• 300 X 300mm Ceramic floor tiles with two varied shades for the field and two different designs for the border.
• Fine sand aggregates-already screened
• Portland Cement- 40kgs/bag
• Tile Adhesive
• Tile Grout
• Clean water

Vibro sand and Portland cement

Tile adhesives

300 X 300 ceramic tile 

Tools to be used are:

• Small angle grinder with 4" tile cutter disk
• 24 inches Level Bar
• Tape meter
• Nylon string guide
• Level hose
• Rubber mallet
• Tile spacer- (optional)
• Notched Trowel

Tape measure and angle grinder

METHODOLOGY

• Layout the floor to establish the reference dimension as per the tile installation layout drawing.

• Establish the perimeter finish floor level. This will determine the thickness of the mortar grout.

CLICK the LINK to READ the related article: Tile Installation: Notched Trowel Comb Technique

• Prepare the dry-mix combination of cement and sand aggregates to be used as mortar grout. For the dry-mix mortar grout, the ratio is 1 bag of Portland Cement (40 kg) to 3 cubic feet of fine sand aggregates. When thoroughly mixed, add water slowly then mix again to attain the desired result. 

• Establish the tile setting point (TSP). The TSP is the first tile to be installed serving as the primary guide for the vertical and horizontal layer and eventually the rest of the installation. Careful study must be done for the final location of the TSP. Wrong placement of the TSP will result in an off-centered layout meaning your edges will not be typical or most likely tapered or slanting edges.

• Dampen the floor surface with clean water. Pour cement grout. Place the dry mix mortar to install the TSP with tile adhesive using a notched trowel. Secure the horizontal and vertical layout of the TSP as well as the level by carefully hammering with a rubber mallet.

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• Install the succeeding tile layers with 2mm spacing. If you have 2 tile setter masons, they can install the vertical and horizontal layers simultaneously.

• Always check the level with the level bar layer after layer.

• Continue the tile installation until reaching the wall edge.

• Put in place first the embedded pipes when doing the raised flooring for the washing machine.

CLICK the LINK to READ the related article: Work Inter-Phase: Why Proper Coordination Very is Critical in Construction

• Complete the installation of tiles between the wall edges. Since this is a garage, a ramp is needed. 

• Clean the surface of the tiles from concrete splatter from time to time. When concrete dries on the tile surface, it will be very difficult to clean. If the concrete dries and is removed, it leaves a disgusting dark spot on the tile surface. Allow the concrete mortar grout to cure for 24 hours before applying the grout.

• Our weekend project will never be complete without my wife's serving a special dish for our lunch and spaghetti for our break-time snack.

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