REASONS SOLUTION

COLOUR VARIATION OR NON-UNIFORMITY OF TILED FLOOR

- Use of marble powder of varying whiteness. - Use marble powder of uniform whiteness.- Use of marble powder of varying fineness. - Use marble powder of uniform fineness.- Improper dispersion of pigment. - Ensure proper dispersion of pigment.- Poor grading of aggregate. - Use properly graded aggregate- Laying of tiles from different batches in one room. - Ensure laying of tiles of same lot in one room.

REASONS SOLUTION

CHIPS COMING OUT FROM TILES

- Use of lean mix in facing layer. - Use rich mix, preferably 1:1, for facing layer.- Use of old or set cement - Avoid use of old or set cement- Use of soft aggregate like soapstones etc. - Do not use soft aggregate.- Insufficient curing. - Cure the tiles for 15-21 days.- Poor grinding and improper workmanship. - Ensure proper grinding and better workmanship.

REASONS SOLUTIONYELLOWING OF TILES

- Curing of tiled floor by use of wet gunny bags. - Cure the floor by water pooling and not by wet gunny bags.- Application of wax polish when floor is wet. - Apply wax polish after complete drying of the floor.- Washing of floor with acid or phenol and insufficient - Flush the residual acid thoroughly by washing with water.

flushing of residual acid after washing.- Spillage of water on saw dust. - Ensure no spillage of water on saw dust.- Presence of colouring impurities in cement. - Use JK White Cement, which has no colouring impurities.- Presence of foreign impurities in raw materials. - All raw materials used should be free from foreign impurities.

SOLUTIONCRACKS IN TILES

- High water/cement ratio - Keep moderate water/cement ratio.- Poor grading of aggregates - Ensure proper grading of aggregates.- Use of very fine marble powder. - Use coarse marble powder of approx. 100-150 mesh.- Placing of tiles in direct sunlight after demoulding. - Keep the tiles at moist place after demoulding.- Inadequate curing. - Cure the tiles for 15-21 days.

REASONS

Lit. Ref. JKWC-65 Printed 04/2011

Certified to :ISO 9001 (QMS) & ISO 14001 (EMS)

OHSAS 18001 & SA 8000

MOSAICMOSAIC TILES

Manufacturing ofManufacturing ofManufacturing ofManufacturing of

PROBLEMS & SOLUTIONS

Please also refer our other J.K. White Cement technical literature:-

www.jkcement.com

Contact:Technical Service & Marketing Service

Padam Tower, 19, DDA Community Centre, Okhla, Phase-I, New Delhi - 110020Tel.: 011-49220000 Fax: 011-49220044

Helpline No.:1800 102 8822

E-mail:For CTS: cts.delhi@jkcement.com

For Marketing: jkwc.delhi@jkcement.com

(as per BIS : 1237 - 1989)

TESTS REQUIREMENT

1. Water absorption (Average) 10% Maxi.22. Wet transverse strength 3N/mm Mini.

3. Resistance to weara) For general purpose tile

Average wear 3.5 mmWear on individual specimen 4.0 mm

b) For heavy duty tileAverage wear 2.0 mmWear on individual specimen 2.5 mm

TESTING OF TILES

Mixthoroughly

Mixthoroughly

MANUFACTURING OF MOSAIC TILES

RAW MATERIALS :

PREPARATION OF MORTAR MIX

- J.K. White Cement

- Ordinary Portland Cement : Preferably 43 grade.

- Marble Powder : 100 - 150 mesh, superior whiteness, free

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

distinct from elongated and flaky. It should be graded. It is

important to keep fines or dust as low as possible.

(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

lead pigment is not recommended due to health reason.

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.

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)

(marble chips quantity shall will depend

upon size of chips).

Add sufficient quantity of water to produce mix of

stiff plastic consistency.

1 Part of Ordinary Portland Cement

3 Parts of sand.

1 Part of Ordinary Portland Cement

3 Parts of sand

Add water to make a mix of semi-dry consistency which

should be moist enough for compacting.

- Facing mix :

- Dry backing mix :

- Wet backing mix :

Mixthoroughly

CLASSIFICATION OF MOSAIC TILES

GENERAL PURPOSE TILES

These tiles are recommended for flooring in placeswhere light loads are encountered such as residential buildings, offices, schools, colleges, hospitals etc. Based on designs these tiles are further classified as under :

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.

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.

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

2at higher pressure of more than 140 kg/cm (2000 PSI).

Sizes (mm) Thickness (mm)200 x 200 20250 x 250 22300 x 300 25450 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.

DESIGNER TILES

CHEQUERED TILES

HEAVY DUTY TILES

SIZES OF MOSAIC TILES

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

MOSAIC TILES MACHINERY AND EQUIPMENT 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.

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.

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.

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.

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.

Oil Hydraulic Press :

Vibrating Table :

MS/CI rubber laminated moulds :

Screw Mixer :

Automatic grinding machine :

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.

2Place the mould in hydraulic press and apply minimum 140 kg/cm 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 for15-21 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.

MANUFACTURING PROCESS

After demoulding, tile should be kept in cool or moist place and not under direct sunlight.

Tile should be cured as recommended above.

Curing tank should be cleaned periodically.

Mould should be vibrated sufficiently to release entrapped air.2Each tile should be given minimum pressure of 140 kg/cm during

moulding.

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.

PRECAUTIONS