Losing my thin porcelain virginity - Tile Advice

[Qwerty]

So I was recently asked to fit some 3m x 1.5m 6mm thin porcelain in a new tile showroom. Mapei & Sigma were present to supply tools, materials and their expertise with it.

Well we were naturally apprehensive at first as there were investors, the owner and reps galore present plus it was an all time first for us tilers. This was not a demo day or have a go day, these were full new sheets paid for by the owner, being fitted by me and a couple of others.

The first challenge was setting up the bed/ platform on which to set them down and cut them. This had been 'prepared' for us beforehand by the joiner on site but after an hours fettling by a couple of us and the @Mapei UK Marketing guys we had it as solid and as flat as we could possibly get it with what we had on site. Now in my opinion it wasn't as flat and as solid as it should have been and there was no cushioning on it at all.

Derek from @Sigma UK had the keralift set up ready on top of the stack of slabs outside. The first piece was brought in and laid down safely. Now the area we were tiling was a straight forward 3 tile display which will ultimately be behind the counter (also tiled in a 6mm thin porcelain).

The first piece had to have a section at the top right corner cut out to accommodate the concrete roof truss and a hole drilled at the bottom for the till electric and data cables. 5mm was taken off the bottom also.

We carefully marked out and drilled two holes at the internal angles ready for the cuts. The long vertical cut was scored with the keracut and I then cut the two small cuts by hand with an angle grinder. It was then snapped at the end using the sigma breaker. The edges were then polished and then the 5mm was taken off the bottom and again polished.

It was then time to load the frame back on and offer it up.



Perfect fit! We were fortunate enough to have 6 guys to hand for the lifting and manoeuvring. Tools and static tiled display bays were the issue rather than the lifting but we had to work fast due to the suction of the cups potentially slowly releasing.

The wall was trowelled up with Mapei Ultralite and the back of the tile also. It was then lifted into position and gently bedded down into the adhesive.

Level sorted and then continue with tiles 2 & 3. Neither of these required cutting apart from tile 3 in the top left for more cables.

All in all it was a great learning experience. Mapei had some great advice regarding products for large format and they had a great level of knowledge about it all. Derek was spot on with the equipment and was also a font of knowledge!

A few days later a couple of us started on the counter in the same 6mm porcelain (but in a carrera marble effect). Again the joiner had made the counter. I personally would have liked to see it covered in backerboard but it was 18mm ply with a solid framework inside. We sorted out a few of the protruding screws and high spots and took a deep breath before starting!

The keracut and breaker was used to cut the tile almost in half length ways. It went well until cut sheared off and created an elliptical shaped break in the middle! All not lost as there was going to be a good 8cm wastage on one side of the tile anyway and the area where it was happened to be on the closing angle on top of the counter where it turns 45°. The pieces were cut to size again with a 10mm overlap on all sides to be mitred. Mitres were then cut freehand using the grinder.

Sadly I wasnt there to complete the final cuts as another local tiler I was with that day stayed on to finish it all off as I had to shoot on but all in all we were pretty happy with how it turned out.

 

[One Day]

'Fun' isn't it?!
Great post too.

 

[Qwerty]

Certainly different!

 

[One Day]

I still get nervous every tile.
Emotionally and physically exhausting on a level you just don't get with day to day tiling, but it's kind of addictive too and the satisfaction level makes up for the added stress.
And you get paid sometimes too!

 

[Old Mod]

Very nice Geoff, thank you.
It does look really good.
Who finished it, Chris?
Sounds like you enjoyed the experience, which is kool.
The Mapei Ultralite, is that a rapid?
The cut where it went off line, was it scribed in one motion or two?
I’ll mention one piece of advice tho, not just for you, but for anyone trying this for the first time.
The handling is by far the most important aspect of the work, so when you’re placing a piece on the table for fabrication, walk it to the table on its longest edge as you appear to have done.
However, don’t then lift it on to the table, lean it against the table and pivot it against the table by picking it up from the bottom edge til it’s flat and then slide it on.
It’s a lot lighter that way too.
You run the risk of fracturing it every time it’s carried on its back, which is effectively what you do by physically lifting it on.
Use the table as a pivot point to support the centre, and slide rather than lifting it, eliminating as many risks as possible gives you a less stressful install.
Sound s like you really enjoyed it, which is half the battle.
Well done mate.

 

[Old Mod]

Yeah, even 4mm wedi would have been a good shout Geoff.

 

[Old Mod]

I still get nervous every tile.
Emotionally and physically exhausting on a level you just don't get with day to day tiling, but it's kind of addictive too and the satisfaction level makes up for the added stress.
And you get paid sometimes too!

I hear that Mark, I’ve never worked so hard, both physically and mentally.
Nothing is as stressful, especially with the absence of spare material when dealing with something like a string or bookmatch set.

 

[Qwerty]

@3_fall .... Wayne Hardy did the hard work on the counter. He's a top lad

All scoring was done in one motion with the wheel on the tile at all times, but you may well have a point there as we took over the scribe in the middle of the tile. Possibly the cause?

The Ultralite is a rapid, but it was fine in the low temperatures we were working in.

I know what you mean about the lifting, heavy and awkward sums it up!!

 

[Dumbo]

I going to be working down Geoff's way soon . I will swing by and take some of those unflattering photo's that we get on here taken from inch away asking if it ok

 

[Old Mod]

@3_fall ....
All scoring was done in one motion with the wheel on the tile at all times, but you may well have a point there as we took over the scribe in the middle of the tile. Possibly the cause?

Yeah when the slab is scribed, and it’s not done in one continuous motion, the point at where the carriage hesitates or stops can cause an irregular scribe and a point of fracture, especially when two people take part.
The downward pressure on the carriage will change and can cause the slab to break in an irregular shape.
This is what frustrates me a little with these experience days, don’t get me wrong, I really like Derek and I have a lot of respect for the man, but its little things like that, that they forget about and it’s easily overlooked, but it’s something that is very important.
It doesn’t help when videos these companies produce, show bad technique.
I certainly don’t pretend to know more than these guys, but I do know what can cause breakages, it’s a road frought with danger when you’re trying to get your head around this stuff.
Firstly they’re in controlled environments, and they could give a crap if they break one, they just go get another, not quite so easy for the likes of you and I.
The last slab that I had to have replaced on site was at a 25% discount, client was elated when it only cost £545
Repetition is your best safeguard against things going wrong, once you find a way to cut that particular batch, stick to it religiously throughout the install, but be prepared to change your technique or cutting equipment with each new install, even if it’s the same range of tiles, it means nothing.
We have to test the water with every single new batch.

And yes, not covering the table, bad idea generally, nothing to absorb vibrations that are transmitted through the slab when fabricating it.

But to be honest Geoff, the only guys that have serious issues with this type of material are those that have been Tiling
“all my life, I know how to cut a tile!”
and I know that’s not something something you’d ever say, you’ll enjoy your next experience even more, I’m sure.

Very informative post, thank you.

 

[Waluigi]

Great Post, Plan Tec

........and some interesting pointers on how to install this stuff.

My local showroom had a thin porcelain display a few years ago so I thought it would start to hit the market near me but unfortunately it was covered up due to customers bypassing the showroom and being sold direct from the supplier plus the fact that the showroom couldn’t find people to install it. Maybe that’s starting to change.........

 

[One Day]

I've found that too. At least half seems to be bought direct from the manufacturer. I suppose such a high value item makes it more worthwhile. Savings are good too.

 

[Italy]

@3_fall .... Wayne Hardy did the hard work on the counter. He's a top lad

All scoring was done in one motion with the wheel on the tile at all times, but you may well have a point there as we took over the scribe in the middle of the tile. Possibly the cause?

The Ultralite is a rapid, but it was fine in the low temperatures we were working in.

I know what you mean about the lifting, heavy and awkward sums it up!!

I used slow ultralite s2, it was the month of August it was still very slow

 

[Old Mod]

I've found that too. At least half seems to be bought direct from the manufacturer. I suppose such a high value item makes it more worthwhile. Savings are good too.

I feel manufacturer’s are at fault here, I think it limits its availability.
I find it’s only clients with seriously deep pockets that go direct to manufacturers, the rest seem to be kind of impulse buys of 2/3 slabs.
What purpose does it serve undercutting their outlets, they just don’t bother pushing it after they find out why they’re loosing sales.
The manufacturers still get their money through an outlet, I find it hard to believe it increases their sales that much that it’s worth trampling over their stockists/suppliers.
Praps I’m wrong, praps @Paul C. would be able to shed more light on the subject.
I appreciate the client gets discounted products, but I feel that long term it’s limiting the number of clients because the material isn’t in plain view for everyone to see.
It comes down to only those who know about it that will use it.
I find 90% of people that I encounter and who are not actually the client, have never seen it or are even aware it exists.
That’s not a scenario that’s going to increase my client base.
But I think that’s a whole new thread for discussion and I’m rambling.
Yeah, nothing new there either.

 

[One Day]

Agree Marc, I can't understand why they sell direct either.
Brexit effect??? @Paul C. will know more I agree.