PROBLEMS & SOLUTIONS
CRACKS IN TILES
REASONS
-
SOLUTION
High water/cement ratio
Poor grading of aggregates
Use of very fine marble powder.
Placing of tiles in direct sunlight after demoulding.
Inadequate curing.
-
Keep moderate water/cement ratio.
Ensure proper grading of aggregates.
Use coarse marble powder of approx. 100-150 mesh.
Keep the tiles at moist place after demoulding.
Cure the tiles for 15-21 days.
Manufacturing of
YELLOWING OF TILES
SOLUTION
REASONS
-
Curing of tiled floor by use of wet gunny bags.
Application of wax polish when floor is wet.
Washing of floor with acid or phenol and insufficient
flushing of residual acid after washing.
Spillage of water on saw dust.
Presence of colouring impurities in cement.
Presence of foreign impurities in raw materials.
-
Cure the floor by water pooling and not by wet gunny bags.
Apply wax polish after complete drying of the floor.
Flush the residual acid thoroughly by washing with water.
Ensure no spillage of water on saw dust.
Use JK White Cement, which has no colouring impurities.
All raw materials used should be free from foreign impurities.
CHIPS COMING OUT FROM TILES
REASONS
-
MOSAIC
TILES
SOLUTION
Use of lean mix in facing layer.
Use of old or set cement
Use of soft aggregate like soapstones etc.
Insufficient curing.
Poor grinding and improper workmanship.
-
Use rich mix, preferably 1:1, for facing layer.
Avoid use of old or set cement
Do not use soft aggregate.
Cure the tiles for 15-21 days.
Ensure proper grinding and better workmanship.
COLOUR VARIATION OR NON-UNIFORMITY OF TILED FLOOR
REASONS
-
-
SOLUTION
Use of marble powder of varying whiteness.
Use of marble powder of varying fineness.
Improper dispersion of pigment.
Poor grading of aggregate.
Laying of tiles from different batches in one room.
-
Use marble powder of uniform whiteness.
Use marble powder of uniform fineness.
Ensure proper dispersion of pigment.
Use properly graded aggregate
Ensure laying of tiles of same lot in one room.
Please also refer our other J.K. White Cement technical literature:-
Contact:
Technical Service & Marketing Service
Padam Tower, 19, DDA Community Centre, Okhla, Phase-I, New Delhi - 110020
Tel.: 011-49220000 Fax: 011-49220044
E-mail:
For CTS: cts.delhi@jkcement.com
For Marketing: jkwc.delhi@jkcement.com
Certified to :
ISO 9001 (QMS) & ISO 14001 (EMS)
OHSAS 18001 & SA 8000
Helpline No.:
1800 102 8822
www.jkcement.com
Lit. Ref. JKWC-65
Printed 04/2011
MOSAIC TILES
MACHINERY AND EQUIPMENT
The word 'MOSAIC' means the picture or pattern made with small coloured pieces of chips set in white/ coloured concrete. The tiles with this
type of work or pattern are called MOSAIC TILES.
Mosaic tiles are being made in different colours, designs and sizes by using J K White Cement. These tiles are manufactured in hydraulic
CLASSIFICATION OF MOSAIC TILES
MANUFACTURING OF MOSAIC TILES
GENERAL PURPOSE TILES
RAW MATERIALS :
These tiles are recommended for flooring in places
where light loads are encountered such as residential buildings,
offices, schools, colleges, hospitals etc. Based on designs these
tiles are further classified as under :
-
J.K. White Cement
-
Ordinary Portland Cement : Preferably 43 grade.
-
Marble Powder : 100 - 150 mesh, superior whiteness, free
DESIGNER TILES
These tiles are mainly used in residential buildings and are very
popular due to their designs and colourful appearance. These
tiles are locally named as Galicha tiles, Crazy tiles, Veins tiles,
Marble and Granite print tiles etc.
from dust and other foreign impurities.
-
Aggregate :
(a) Facing Layer : The aggregate shall consist of
good
quality marble or other natural stone of similar
characteristics of adequate hardness, angular in shape as
CHEQUERED TILES
distinct from elongated and flaky. It should be graded. It is
These tiles are used where non-skiding function is required such
as foot paths, ramps, passages, swimming pools, stair cases
and entrances of the building etc. These tiles may be with or
without stone chips and pigments.
important to keep fines or dust as low as possible.
HEAVY DUTY TILES
These tiles are recommended for heavy traffic conditions such
as foot-paths, storage godowns, car parkings, cinema halls,
auditoriums and industrial floors etc.
These tiles are made with the use of quartz powder, quartz chips
and ironite (Ferrous substance) in place of marble powder and
marble chips respectively. These tiles are hydraulically pressed
at higher pressure of more than 140 kg/cm2 (2000 PSI).
(b) Backing Layer : Graded Natural stone or crushed gravel
should be used as aggregate.
-
Sand : Natural coarse sand clean or duly cleaned.
-
Colouring Pigments : Synthetic inorganic pigments or
cement colours/oxide colours, should be used. Use of
MANUFACTURING PROCESS
lead pigment is not recommended due to health reason.
Pour facing mix in mould to a depth of 6-8 mm.
vibrate the mould lightly.
Spread the dry backing mix evenly over the above layer to a depth of 2-3 mm so that it can absorb
excess slurry brought up on the surface due to vibration of facing mix.
Fill the remaining depth of mould with wet backing mix to a proper level.
Place the mould in hydraulic press and apply minimum 140 kg/cm 2 pressure.
After pressing, remove the tile from mould gently on the pallet and transfer to the rack.
Store the tiles in cool and moist place for 24 hours. Afterwards keep these tiles under water for
15-21 days for curing.
Grind the tiles on grinding machine by keeping the surface of tiles wet. Properly sieved sand should
be used as grinding media.
Grout the tiles to fill up imperfections, if any, with neat white or coloured cement slurry. Air dry these
tiles for 24 hours. Afterwards keep them in moist condition for 3 days.
The tiles are now ready for despatch to customers.
Pigment shall not contain zinc compounds or organic
dyes.
-
Water : Should be of potable quality, clean, free from salt,
foreign impurities, dust, dirt, grease etc.
SIZES OF MOSAIC TILES
Sizes (mm)
Thickness (mm)
200 x 200
20
250 x 250
22
300 x 300
25
450 x 450
30
Besides the above sizes, Mosaic tiles of different shapes and
sizes can be manufactured as per the agreement between
buyer and manufacturer.
Oil Hydraulic Press : Use of oil hydraulic press is recommended due to
following reasons :
a) Constant pressure is obtained.
b) Maintenance cost is minimised.
c) Timely desired pressure is obtained.
Vibrating Table : Giving Vibration to tiles during moulding helps to
release entrapped air. Tile is properly compacted. It will have better
strength and resistance to wear and tear.
MS/CI rubber laminated moulds : These moulds are becoming popular
due to :
a) Low maintenance cost.
b) Eliminates use of demoulding agent.
c) Stops leakage of cement mortar from mould during pressing.
d) Obtains sharp edges of tiles.
Screw Mixer : Use recommended :
a) For achieving proper mixing of backing layer.
b) Ensuring uniform mixing of cement with sand and aggregate
particles.
c) Saving in cement.
Automatic grinding machine : Better grinding operation gives high
class finishing on surface without imperfections or cut marks. It also
increases the rate of production. Washing of tile is done automatically
during grinding operations.
PREPARATION OF MORTAR MIX
-
Facing mix :
1 Part J.K. White Cement
1 Part Marble Powder
2-3 Part of marble chips of graded size
(Colour of chips to suit design)
Mix
thoroughly
(marble chips quantity shall will depend
upon size of chips).
Add sufficient quantity of water to produce
mix of
stiff plastic consistency.
-
TESTING OF TILES
After demoulding, tile should be kept in cool or moist place and not
under direct sunlight.
(as per BIS : 1237 - 1989)
Dry backing mix :
1 Part of Ordinary Portland Cement
Tile should be cured as recommended above.
1. Water absorption (Average)
10% Maxi.
Curing tank should be cleaned periodically.
2. Wet transverse strength
3N/mm2 Mini.
Wet backing mix :
Mould should be vibrated sufficiently to release entrapped air.
1 Part of Ordinary Portland Cement
Each tile should be given minimum pressure of 140 kg/cm2 during
moulding.
3. Resistance to wear
a) For general purpose tile
Average wear
Wear on individual specimen
3.5 mm
4.0 mm
3 Parts of sand.
-
PRECAUTIONS
3 Parts of sand
Mix
thoroughly
Mix
thoroughly
Add water to make a mix of semi-dry consistency which
should be moist enough for compacting.
Proportion of cement to aggregate in backing layer should not be
leaner than 1:3 by mass.
Thickness of facing layer should be such as to provide final thickness
of 8mm after grinding.
TESTS
b)
For heavy duty tile
Average wear
Wear on individual specimen
REQUIREMENT
2.0 mm
2.5 mm