Structured Method Statement for Ceramic Floor Tiles Table of Contents 1. PURPOSE 2. SCOPE 3. REFERENCES, STANDARDS & SPECIFICATIONS 4. DEFINITIONS AND ABBREVIATIONS 5. RESPONSIBILITIES 6. PROCEDURE 7. MATERIALS 8. MANPOWER 9. TOOLS AND EQUIPMENT 10. EMERGENCY /INCIDENT PROCEDURES 11. ATTACHMENTS 1. PURPOSE This method statement defines the activities and the sequences which are to be carried out and to describe in general, the methodology to be used in work execution related to ceramic floor tiling works for (Name of Project) to ensure compliance with the conditions of contract, contract specifications and Health, Safety and Environmental requirements consistent with the approved drawings, relevant specifications and BOQ. 2. SCOPE This method statement specifically addresses the ceramic tiling works in general for (Name of Project) at (Locations in the project) and as shown in the drawings. 3. REFERENCES, STANDARDS & SPECIFICATIONS Project specifications and BOQ Project Quality Plan Project HSE Plan Quality Control Procedures Contract Drawings and Specifications Manufacturers’ brochures/ literature and other details as a part of this method statement. All work shall be executed in compliance with the requirements of Project Specifications & Emergency Response Procedures, and other applicable standards Approved drawings for constructions with code A and B for works, materials approval submitted/ to be submitted as applicable and related approved method statement & ITP’s (Inspection and Test Plan) 4. DEFINITIONS AND ABBREVIATIONS xxxxx Consultant xxxxx Contractor PM Project Manager CM Construction Manager PE Project Engineer QCM Quality Control Manager QCE Quality Control Engineer SM Safety Manager SR Surveyor SF Section Foreman QCP Quality Control Procedure ITP Inspection and Test Plan ITL Independent Test Laboratory BOQ Bill Of Quantities MS Method Statement FM Form NCR Non-Conformance Report ITR Inspection & Test Request 5. RESPONSIBILITIES The Project Manager is responsible for the preparation and approval of this work procedure. The Construction Manager and/or his nominee are responsible for the overall execution of the works in accordance with the steps outlined in this procedure and consistent with the approved project schedule. He shall be responsible for the controlling the coordination between all involved parties to ensure Safety, Quality, controlling the progress of work, civil and MEP clearance prior to start tiling work and to ensure final approval is obtained prior to starting next activity. Notifying QC engineer and issuing the checklist (inspection request for approval/checklist – Annex A, including all clearances as applicable in a timely manner when work is ready for inspection. Accompanying the Engineer’s representative for ongoing inspection and obtain his approval to proceed with next activity. The QA/QC Department is responsible for the overall inspection and documentation of works in compliance with the work procedure and Project Specifications and shall be responsible for coordination with Client/Consultants for inspection activities and close out of the NCR/ SON, if any, with Consultants representatives. The Survey Department is responsible for all the layout I setting-out and establishing the reference elevations related to the work. 6. PROCEDURE The scope of Work for Tile Installation 1. Materials Handling on Worksite and Storage Materials shall be received in parts as per site requirements and in standard boxes and/or packs, pallets etc. Materials shall be stored in the proper way and handled as per manufacturers’ recommendations if any. Obtain each color, grade, finish, type, composition, and variety of tiles from the single source. For grout and setting materials, obtain ingredients of uniform quality from one manufacturer for each cementitious and admixture component and from one source or producer. 2. Preliminary in Tiling Works Work shall comply with all project specifications, rules, regulations, laws, and ordinances of all authorities having jurisdiction. Tiles type & color, mortar mix, grout, adhesives, etc., shop drawings and method statements shall be approved by the consultant prior to commencing any tiling works. Tiling mockup shall be arranged for final approval at the location designated by the consultant. Approved mockup and sample shall be preserved and always readily available at the site during the entire duration of the work. Ensure that the MEP clearance is obtained for the particular tile work area. In wet areas, ensure that the waterproofing is completed and tested for leakage & any applicable inspections. Obtain the required safety and health clearance from Safety Department prior to starting the work. Restrict the area from foot and wheel traffic prior to and during the tiling, activity to prevent damages from the finished work. Inspection requests (checklist Annex A) along with the key plan showing area to be executed will be raised to Engineers progressively for the tiling/flooring works. All inspections will be carried out in phases to cover a part of the total work. 3. Worksite Preparation The areas of the concrete substrate to be tiled are to be brushed clean and dampened and the finished floor level is to be established. The mortar for bedding the tiles shall be as shown in the drawing and/or project specifications. Setting out shall be done by the surveyor and approved by the consultant. Engage an experienced installer who has successfully completed tile installations. 4. Tiles Installation and Fixing Procedure Laying ceramic tiles by Semi-Dry Mix Method. It shall consist of 1 part of cement to 4 parts of sand by volume to form the sand cement mortar, mixed semi-dry in a mechanical mixer with only sufficient water added to give a crumbly consistency that retains its shape when squeezed in the hand. To maintain the consistency of mix, the volume of water added is to be kept same for each batch. The minimum thickness of bedding with this system of laying is to be 40 mm. The mix is to be spread to a thickness approximately 10 mm greater than that actually required for the bed and be thoroughly compacted by tamping and drawing off to the required level with a screed board which will give even compaction and leveled surface. Only sufficient mortar is to be mixed and spread as can be covered with tiles before it has attained its initial set. A thin layer of the slurry of 1 part cement and 1 part sand, by volume, is to be poured over the surface of the semi-dry mix bedding and spread with a trowel until it is approximately 2 mm thick. Approved adhesive to be applied to the tiles to be laid while the slurry is wet and beaten firmly into position with a wooden beater to ensure a true surface and contact between the tiles and bedding is complete. Get approval for tile layout through dry laying before starting tile work if SOP (Start of Point) is not shown in the drawing. In absence of SOP or approved layout, arrange tiles so that cut tiles occur at wall lines only and are minimum and where they do occur, they are as large as possible. Before tile fixing check that any color, shade variations, and sizes are acceptable. Lay the tiles side by side or keeping specified gap joint by the use of tile spacers as per approved pattern as shown in the approved drawings. The tiles must be correctly positioned at the time they are placed and laid with joints as shown in the approved drawing. Carefully removed the tile spacers after the laid tiles are set enough to prevent difficulties of pulling out the spacers. Tiles shall be placed firmly according to the level shown in the approved shop drawing. Tiles shall be placed firmly according to the level shown in the approved shop drawing. A spirit level should be used to ensure that the tiles are even and level during installation. Accurately form intersections and returns. Perform cutting and drilling of tile without marring visible surfaces. Fit tile closely to electrical outlets, piping, fixtures, and other penetration, collars or covers. Tiles are to be laid level or to 1% falls/or as shown in the approved drawings in “wet” areas, as may be required. Localized variations in level for a nominally flat floor are to be a maximum of +/- 3 mm under a 3 m straight edge. Particular care is to be taken in “wet” areas to prevent low spots and the pooling of water. No soaking is required for fully vitrified tiles or when the adhesive is used. Install edge strip at the following (1.) At openings without thresholds and similar discontinuous edges of thin-set tile floors. (2.) Where ceramic tile floors are adjacent to other flooring materials at the same level. (3.) Where ceramic tile cove base is combined with other types of flooring and (4.) As shown in the drawing. Control and expansion joints: Provide control and expansion joints as per approved Shop Drawings. (1.) Locate control joints as indicated on the approved drawings, but maximum 4.5 meters on center each direction for interior condition and 3.65 meters exterior condition. Provide control joints at all perimeters. (2.) The width of joints must match the width of grout joints. (3.) Seal joints after completion of tile work. Do not saw-cut tiles control/expansion joints after installation the tiles. 5. Joint Grouting The grouting mix shall be an approved grout as per submittal ref.: (reference goes here). Grouting of the joints shall be carried out after 24 hours of the completion of the laying of the tiles so that the grout will attach itself firmly to the bedding. Care should be taken to avoid disturbing the tiles during grouting application. Clean the joint before filling with approved grout. Apply tile grout to the joint spaces between tiles using a sponge or soft cloth. 6. Cleaning of Finished Work Remove excess grout, setting bed material, mortar, adhesive with clean clothes or sponge. Clean the affected surface area when mortar and adhesive are still in wet form by cotton waste or any other such material. When the mortar, grout, and adhesive were dry, remove them with scrapper lightly and clean with dampening cotton waste or cleaner as specified by the manufacturer. Clean all tile surfaces and remove cement/tile grout residue from tiles as soon as day’s work is finished. 7. Protection and Preservation of Finished Work Remove defective tile and replace with sound tile. Remove and replace tiles with hollow bearing sound when tapped with steel rod after installation. Prohibit traffic until tiles are completely set. Cover floor area with hard boards, tarpaulins, plastics or gypsum powder to prevent damages to the installed tiles and preferably area has to be barricaded or restricted for normal entry or by locking the area. Repairing of damaged tiling work: If by any reason, any tile is broken or damaged, remove the tile and replace with sound and similar tile. 7. MATERIALS 1. Approved materials for various types of tiles such as unglazed ceramic tiles, glazed ceramic tiles, Refer to ANNEX – E 2. Material submittal for adhesive for tiles refer to ANNEX- C 3. Cementitious grout for tiles for general purpose refer to ANNEX- D 4. Cement, sand, water etc. Portland cement: ASTM C150 Type 1 Sand: ASTM C 144 natural or crushed stone Grout Sealer, Latex Additive, Cold Applied Waterproofing, Aluminum trims & Acid Cleaner 8. MANPOWER The sufficient number of workers will be employed as per site/planning requirement to perform their duties and they will have sufficient tools to tackles the work assigned to them. Mason/Tile Setter Helper/Laborers Foreman 9. TOOLS AND EQUIPMENT Tape Measure Framing Square Marker Rubber Gloves Screed Board Buckets Tile Trowel Rubber Mallet Sponges Tile spacers Chalk Line Carpenter’s Triangle Gloves Safety Glasses Manual Tile Cutter Tile Cutter Tile Nipper Grout Float Spirit Level One-bagger mixer Mechanical mixer for dry mixing Scrapper
