Laying of large-format tiles in wall and floor areas

The ceramic industry is advancing in its technical progress and, in line with the trend, is producing ever large-size tiles by using special processes, which are often also becoming ever thinner. The client wants flat coverings with as few joints and narrow joint as possible, some of which are not feasible. In addition to above-average expertise, this type of installation requires special knowledge, creativity and, last but not least, special tools. In particular, the substrate assessment is an important aspect, since it often requires additional levelling to improve the surface evenness in the wall or floor area.

Simple & safe to the goal

  1. Substrate preparation

    1. Check floor surfaces for evenness by using an electric hose level or laser device. For better orientation, fixed points might be defined, if in order to indicate the necessary thickness for levelling and to ensure optimal evenness.

  2. 2. In case of calcium sulphate screeds, the mixing water of the tile adhesive must not penetrate into the substrate. The residual moisture must not exceed 0.5% by weight before installation. For this type of substrate, apply two coats of the quick-drying multi-use primer weber.prim 804.

  3. 3. In the wall area, small-surface unevenness can be levelled with appropriate adhesive mortar, such as the multi-use flexible tile adhesive weber.xerm 861. For larger levelling jobs, it is recommended to use the quick-setting levelling and repair mortar weber.plan 818.

  4. 4. For levelling surfaces, it is absolutely necessary to apply an additional coat of the floor self-levelling compounds weber.plan 813-10 (1 - 10 mm) or weber.plan 813-25 (1 - 25 mm). Refer to the application tip "Application chart of weber.plan 813" for full information about specific primer and leveling thickness in accordance with each substrate.

  5. Priming

    1. Apply the primer weber.prim 801 on absorbent substrates or the primer weber.prim 803 on non-absorbent substrates. The quick-drying multi-use primer weber.prim 804 can also be used for pre-treatment of all substrates.

  6. Preliminary works

    1. For drilling or cutting installation holes, etc. the use of special diamond core bits and cutting discs in the appropriate sizes is strongly recommended as a real relief. If necessary, appropriate templates should be prefabricated from cardboard or similar beforehand.

  7. 2. With increasing format sizes, it is becoming more and more difficult to achieve full-surface contact with thin-bed tile adhesives. Therefore, it is imperative to choose the combined laying method (floating-buttering method). Larger formats require an increasing consumption of adhesive mortar.

  8. Application on walls

    After the tile adhesive has been combed over the entire surface of the wall area and on the backside of the tiles, the ceramic covering can be laid onto the fresh mortar bed of weber.xerm 861. A slight knocking or sliding motions will achieve the best possible contact (i.e. full-surface between tile and adhesive).

  9. Application on floors

    Large-format, thin tiles must be covered with a fabric backing on the reverse side in order to be used on floors. In this case, such tiles are also installed with the temperature-independent setting flexible adhesive weber.xerm 859 F in the floating-buttering method.

  10. Resumption

    The contact between the tile and mortar bed must be cut with an appropriate wire. Only then the already laid tiles can be picked up from the fresh adhesive bed.

  11. Joints

    1. The joint width should not be undersized due to the ever-decreasing joint proportions in the covering and should not fall below 3 mm in the entire cross-section. If necessary, movement joints can be formed with appropriate joint expansion profiles for visual reasons.

  12. 2. Work the premium grout weber.fug 875 BlueComfort into the joints flush and deep with a hard rubber float on walls and floors. After a few minutes, apply a very small quantity of the grout. Smooth down the surface with soft diagonal movements and remove excess material.

  13. 3. Clean the grouted joints with a latex sponge or a felt float.  Eventually, a supplementary cleaning operation with clean water is necessary in order to avoid any eventual dried mortar haze or residues.

  14. 4. Connection and movement joints must be closed with the elastic silicone joint sealant weber.fug 880 or weber.fug 881. In the case of natural stones, use the specific sealant weber.fug 883. For better bonding, use the primer weber.fug 884 (absorbent joint sides) or weber.fug 885 (non-absorbent joint sides).

  15. Tools

    Special types of installation also require special tools, such as: glass suction cups, cutters, hand wire, grinding pads as well as appropriate holding and carrying devices, etc.

  16. Supplementary service

    For levelling work on larger-size surfaces, we offer you a special service: the mini pump truck. For more information, ask our Export Department or our Technical Department for Applications.

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