Santa Ana Terracotta Laying and Sealing Instructions
Tools required: Angle Grinder, Sponges, Cloths, 4" Paint Brush, Shining Brush, Squeegee, 10mm Comb, Water Bucket. If using a wet saw, cut tiles must be dried with a dry cloth or else salting will occur.
1. Tiles look much lighter in the box, than they do after treatment with the Brown Sealer. They should be stored inside as rain will cause the boxes to disintegrate and the tiles to effloresce. Stack tiles upright, and not on the flat, to prevent breakages. Rough edges. pitting and chipping are not defects, but a characteristic look of these tiles.
2. Decide on the pattern to be used i.e. square, diagonal, brick etc. Ask for details when expansion joints are required. These are required when an extension is added to the floor of an existing house, along the wall where a Patio Door meets the existing floor, or in Door Openings if Saddles are not used
3. On the first day fix the tiles to a well-cured base(6 weeks old, B.S. Regulation). Use a good quality, Rapid-set floor adhesive. Follow the manufacturer's instructions. The adhesive should be combed to a depth of 10mm on the floor, and the backs of the tiles should be buttered as well ,as they are bevelled so as to achieve the maximum adhesion and support for the tiles. Grout space should be 8 to 10mm and not greater than 15mm or else the grout will sag in the middle. This gives enough play as the tiles are not four square. Use a wide joint Grey Grout with the Brown Sealer. If using Linseed Oil as a sealer, use Sandstone Grout (Looks better). Use an Angle Grinder to cut the tiles which is much quicker than using a wet saw, as the edges have to dry out.
4. Wipe the dust off the surfaces of the tiles with a clean towel before applying the Brown Sealer. Apply the Brown Sealer to the tiles with a 4" Paint-Brush, the length of your arm at a time. Do not overload the brush. Apply sparingly. It will soak in quite quickly. Brush lines will appear. These should be rubbed away with a clean towel. Suggest you treat six tiles at a time and then rub over with a clean towel. Repeat until the entire floor is covered. It will be dry in three hours. Suggest you leave it over-night to harden if drying conditions are poor, otherwise grouting can begin. Leave used rags outside the house to avoid self combustion.
5. Mix the grout to a pasty consistency according to the manufacturer's instructions. (If it is too watery, salt will occur in the grout) Pull the grout into the spaces with a squeegee and level off. The grout should be flush with the surface of the tiles, and not recessed. This is achieved by allowing the grout to dry out longer. Remove the surplus grout with a series of clean sponges and buckets of water. Do not slop water all over the tiles as this will cause salting. Wipe with a damp sponge and rince clean every time. Allow the grout to dry out and harden i.e. 48 - 72 hours or longer. Protect floor from other trades with 8' x 4' hardboard or block off the room.
6. On the day the grout has hardened rub off the grout scum with clean towels to reveal the clean matt tiles. Shake the cloth out several times outside the house to remove excess Dust. Apply the Brown Sealer again sparingly, stretching it over the tiles and the grout spaces as well. Remove brush marks by rubbing over each tile with a clean cloth. Allow 5 to 10 minutes to soak in. Rub the tiles with the cloth so that the surface is matt to satin in appearance, not glazed. This stage is critical and the Tiler must not leave the job until the whole floor area has been wiped to a matt finish. Leave used cloths outside to avoid self-combustion.
7. For Pubs, Restaurants, and heavy commercial situations apply the Hardener. Pour into a container and apply to the tiles and grout spaces with a 4" Paint-Brush. Apply sparingly stretching it as far as you can. Do two are three courses of tiles at a time, the length of your arm. Wipe up any excesses if it hasn't dried in after 10 minutes to reveal a matt to satin look. This will eliminate brush marks, which appear on the tiles. Do not use the product if the temperature is less 5 degrees centigrade, as it will not dry out properly. As it is a paint product allow to dry and harden for 12 to 24 hours, depending on drying conditions.
8. The next day, apply a coat of Beeswax with a clean cloth(and not with the shining Brush). Do two courses of tiles at a time (which is approximately the length of your Arm). Allow 5 to 10 minutes to harden. Shine with a large shoe-shine brush. Repeat the process until the entire floor is done. Additional applications of wax give increased hardness and shine.
9. The Client should be left with tins of wax for future maintenance and give my address for a maintenance sheet to be sent to them.
66 Carrigmore Crescent, CityWest,
Fax: +353 12350603 Telephone: +353 12856810
Mobile 087 2623672