2011 TCNA Handbook for Ceramic, Glass, and Stone Tile Installation

Eric Astrachan Tile Council of North America

The Handbook Committee is a collective of industry experts

Manufacturers Sales/distribution Labor Related industry associations Consultants

TCNA facilitates the Handbook process

TCNA receives submission Subcommittee reviews submission Submission revised as needed Handbook Committee votes on submission Committees comments and suggestions incorporated into final version
TCNA experts help rewrite the submission

This revision year

Handbook tripled in size

Operation Handbook Overhaul!

Thank you:
Handbook Committee NTCA & MIA Committees TCNA Technical Committees TCNA Staff Ms. Stephanie Samulski who contributed more than 3000 hours to this project

Whats in the Handbook?

Product Selection Guides
Ceramic Tile Glass Tile Natural Stone Tile Setting Materials Grout Backer Board Membrane Green Building Considerations

Field and Installation Requirements

Substrate requirements Lighting Mortar Coverage Installation flatness and lippage (ANSI and MIA) Grout joint size/patterns (ANSI and MIA) Accessibility Wet area guidelines

Ceramic Tile Selection Guide

ANSI A137.1 summarized
Definitions
Quarry Pressed floor Porcelain Mosaic Glazed wall

Performance requirements
Breaking strength, bond strength, crazing, etc. Abrasion Resistance

Ceramic Tile Selection Guide

ANSI A137.1 summarized
Grade, Sampling Required tests
Water absorption (ASTM C373) SCOF (ASTM C1028) Stain Resistance

Mounting Requirements

Ceramic Tile Selection Guide

ANSI A137.1 summarized
Aesthetic Classifications V0V4

Dimensional requirements
Natural Calibrated Rectified More precise than ISO

Glass tile selection and installation guide

Definitions
Cast Fused Low Temperature

Performance criteria
Impact Resistance, Thermal shock, Abrasion Resistance, etc.

Glass tile selection and installation guide

Emphasis on setting materials
Better mortars needed Longer cure times Uniform mortar depth (flat substrate) Mortar alkalinity of cementitious mortar with low-temperature-coated glass tiles

Glass tile selection and installation guide

Some installation tips
Do not fill hollowshaped pieces Flat substrate required for uniform mortar depth

70 methods now include glass tile as a materials option

Selection Guide info reiterated as bullets
Service Rating Membrane Options Materials
Selection of glass tile Selection of grout and mortar

Movement joints

Natural Stone Tile Selection and Installation Guide

Handbook installation methods/systems for installing tile are already being used for stone NTCA sought stone-specific methods
Clarify which methods are OK Highlight main selection and installation considerations and precautions Make it more obvious natural stone is different

Natural Stone Tile Selection and Installation Guide

Primarily authored by Chuck Muehlbauer, Technical Director for Marble Institute of America Emphasis on selecting stone for the given application

Natural Stone Tile Selection and Installation Guide

Natural stone defined
has been harvested from its in-situ position, cut and machined without altering the natural fabric has a nominal thickness of less than and no facial dimension greater than 2

Does not include agglomerates and other engineered products or stone that does not meet the dimensional requirements

Natural Stone Tile Selection and Installation Guide

Water-sensitivity Acid Sensitivity Fiberglass mesh reinforced stone Soundness of Marbles Filled Voids in Travertine Pinholes in Marble Variation in Abrasion Resistance

Natural Stone Tile Selection and Installation Guide

Delamination Anisotropy Shading and Variation Efflorescence Water Spots Stone Finishes Staining issues Sealers, impregnators, and color enhancers

Filled Voids in Travertine

Voids/holes, often filled w/cementitious or resinous filler Particularly for cross-cut tiles, many voids can exist just below finished surface, preventing detection and filling in the factory.

Filled Voids in Travertine

Concentrated load or point load will fracture the thin shell of stone High-heeled shoes and wheeled carts are common offenders Maintenance to fill voids as they appear over time will be required when such stones used.

Pinholes in marble
Many marbles have pinholes visible in the face of the material. As many as 100 or more per square foot. Not a defect Proper sampling required

Expectation of Shading and Variation

Stone is a product of nature with inherent variation in color, shade, and character Piece to piece variation is characteristic and acceptable Several pieces should be supplied as a sample
Samples should be current Range of stones actually supplied should be reviewed and accepted prior to installation.

Expectation of Shading and Variation

Dry laying pieces before installation helps ensure a pleasing blend Not always feasible Not required or expected unless specified in writing by the project superintendent or owner

Handling Shading and variation

Blend material from multiple packaging units to distribute the variation throughout the project and to avoid a blocking effect For larger projects, may not be feasible to view pieces from the full lot Project superintendant shall coordinate with the tile contractor to determine viewing and acceptance procedures

Handling Shading and variation

Superintendant is the owners representative on the jobsite and must identify issues immediately Contractor is responsible for blending tiles, but not for future issues arising over shade differences or individual stone pieces Suppliers typically will not address issues of shade variation and acceptability after installation.

Natural Stone Tile Selection and Installation Guide

Selection of other materials
Use epoxy mortar for moisture-sensitive stone and fiberglass mesh reinforced stone Use white setting materials for light stones Use unsanded grout for soft stones

55 Stone Methods
Selection Guide info reiterated as bullets
Service Rating Limitations Materials
Selection of stone tile Selection of grout and mortar

Requirements Prep by Other Trades Notes

Setting Materials Selection Guide

New medium bed mortar definition ISO product specifications listed for each applicable setting material type
Example: latex/polymer modified mortar can be specified per ANSI A118.4 or ISO C criteria

Grout Selection Guide

New Premixed Polymer Resin Grout definition New epoxy emulsion grout definition New section on stain-resistance and color consistency of cementitious grouts ISO product specifications listed for each applicable setting material type
Example: cementitious grouts can be specified per ANSI A118.6, A118.7 or ISO CG criteria

More on ANSI and ISO

TCNA Grout/Mortar Subcommittee determined minimum performance required for each Handbook installation method Materials must meet one or the other Cannot be correlated
Different properties are measured Different tests used to measure properties

More on ANSI and ISO

ANSI product standards available from TCNA ISO products standards available from ISO Handbook Appendix A
Provides key to ISO nomenclature Provides testing/performance requirements for the materials to meet the designations

Green Building Standards and Rating Systems Guide

LEED CHPS ICC-700 IGCC Recycled content Regional availability Indoor Air Quality Exterior Contribution Cleaning and Maintenance Durability Life Cycle Performance Innovation

Tile is the Natural Choice Brochure

Updated for 2011
Expanded to Encompass Tiled Finishes as a Whole Tiles and Installation Materials

General Information on Environmental Sustainability of Tiled Surfaces Information on LEED and Other Green Building Standards/Rating Systems 12 Reasons to Choose Tile Independent Life Cycle Cost Analysis of 17 Floor Coverings

Important Field & Installation Requirements

Maximum allowable deflection Natural Stone on post-tensioned concrete Natural Stone over wood substrates Proper spacing of wood subflooring and wood underlayments Subsurface tolerances

Important Field & Installation Requirements

Lighting Coverage Flatness and Lippage Grout joint size and pattern considerations Accessibility Wet Areas Guidelines

Maximum Allowable Deflection

Code complianceIBC, IRC Owner and design professionals responsibility to plan for live and dead loads Tile contractor not responsible for failures of overloading

Floor Installation Weights

Dead LoadThe weight of materials of construction incorporated into the building, including floors Tile and installation materials are included Design professional must also include substrate materials Sometimes the tile is the last straw

Floor Installation Weights

Appendix B
Assumptions used in calculations Weights of individual installation components

Using the weights provided and Appendix B, design professionals can accommodate the weight of the installation method chosen, including when actual components weigh more or less than the typical weights provided

Floor Installation Weights Examples

Popular ANSI standards: Lippage

Lippage in Natural Stone Installations

Lippage in stone tile flooring is accentuated
tighter joints slight or no chamfer high gloss, polished finish

Allowable lippage between adjacent units of smooth finished natural stone is 1/32

Popular ANSI standards: Minimum grout joint width for ceramic tile installations
At least 3 times the actual variation of facial dimensions of the tile supplied Not less than 1/16 To accommodate the range in facial dimensions, grout joint size may, of necessity, vary from grout joint size specified

Minimum grout joint width example

Tile with a 1/16 variation in facial dimensions requires a 3/16 or wider grout joint 1/16 (amount of variation) .x 3 3/16 Based on field measurement of dimensions

Minimum grout joint width for Natural Stone Tile Installations

Not less than 1/16 Stone is machined to size and generally has less variation in facial dimensions

Popular ANSI standards: Running Bond/Brick Joint Patterns

For tiles (square or rectangular) with any side greater than 15
minimum 1/8 grout joint for rectified tiles minimum 3/16 grout joint for calibrated tiles

Popular ANSI standards: Running Bond/Brick Joint Patterns

Increase the minimum width of the grout joint by the amount of edge warpage on the longest edge of the actual tiles being installed.

Popular ANSI standards: Running Bond/Brick Joint Patterns

Example: 1/8 (baseline minimum for rectified tile) + 1/32 (edge warpage, long side of actual tile) 5/32 (average minimum grout joint allowed) Some grout joints will be less/more than the average minimum to accommodate the specific tiles supplied.

Running Bond/Brick Joint Patterns when offset side is 18 or longer

For tiles (square or rectangular) where the side being offset is greater than 18 (nominal) the offset will be a maximum of 33% unless otherwise specified by the tile manufacturer.

Running Bond/Brick Joint Patterns when offset side is 18 or longer

If an offset greater than 33% is specified, specifier and owner must approve mock-up and lippage.

Running Bond/Brick Joint Patterns in Natural Stone Tile Installations

Not an issue due to warpage IS an issue due to installation and uneven substrates

Increasingly large tiles have led to NEW substrate flatness tolerances for thin-bed methods
Old tolerance
in 10 and 1/16 in 1 from the required plane

Increasingly large tiles have led to NEW substrate flatness tolerances

NEW: For tiles with all edges shorter than 15
in 10 from the required plane no more than 1/16 variation in 12

NEW: For tiles with at least one edge 15 long

1/8 in 10 from the required plane no more than 1/16 variation in 24

Substrate Flatness for Natural Stone Tile Installed with a Thin-Bed Method
1/8 in 10

Substrate flatness for mortar bed and self-leveling methods

in 10 for ceramic tile and stone Realistically, these methods can accommodate even a little more variation, especially mortar beds

Mortar Coverage
Ceramic Tile
80% in dry areas 95% in wet areas Evenly distributed to support edges and corners

Natural Stone
95% with no voids exceeding 2 in No voids within 2 of tile corners All corners and edges fully supported Back-buttering recommended

Avoid Excessive Mortar and Non-Uniform Mortar Depth

Particularly for softer marbles, limestones, and travertines, uneven mortar shrinkage can cause a fine but visible crack Larger glass tiles also vulnerable Medium-bed mortar can help, but is not intended for truing or leveling Substrate preparation, mortar bed, or self-leveling methods should be considered

Wall Wash Lighting

Lights located at wall/ceiling interface or mounted on the wall Produces shadows and accentuates acceptable lippage and warpage Same effect on floors from natural lighting

Does it Matter?

Wall Wash Lighting Does it Matter? You Bet!!!

Environmental Classifications
Designations applied to each method
Res for residential Com for commercial

Residential vs. commercial

Greater water exposure in commercial applications To avoid confusion where floors have a residential service rating

Res1 (Residential Dry)

Residential application that will not be exposed to moisture or liquid except for cleaning purposes. Examples: Floors in rooms with no direct access to the outdoors and no wet utility function: living rooms, dining rooms, and bedrooms; dry area ceilings, soffits, decorative/accent walls, fireplaces, some backsplashes and some wainscots.

Com1 (Commercial Dry)

Commercial installation that will not be exposed to moisture or liquid except for cleaning purposes. Commercial cleaning and maintenance practices typically generate greater water exposure than residential practices. Examples: Floors in areas with no direct access to the outdoors and no wet utility function, such as hallways; dry area ceilings; soffits; decorative/accent walls; corridor walls.

Res2 and Com2 Limited Water Exposure

Tile surfaces that are subjected to moisture or liquids but do not become soaked or saturated due to the system design or time exposure. Residential examples: Floors in bathrooms, kitchens, mudrooms, laundry, and foyers, where water exposure is limited and/or water is removed; some backsplashes, some wainscots, some countertops Commercial Examples: Floors in bathrooms and locker rooms; some backsplashes and other walls, such as bathroom walls and wainscots where water exposure is limited and/or water is removed.

Res3 and Com3 Wet areas

Tile surfaces that are soaked, saturated, or regularly and frequently subjected to moisture or liquids. Residential examples: Shower floors; floors and other horizontal surfaces where water is not removed or drained, such as some countertops; tub walls and shower walls. Commercial Examples: Tub walls, shower walls and floors (not including gang showers), and some commercial kitchen floors and walls.

Res4 and Com4 High Humidity, Heavy Moisture

Tile surfaces that are subject to continuous high humidity or heavy moisture exposure.

Res4 and Com4 High Humidity, Heavy Moisture

Residential examples: Intermittent-use steam shower walls, ceilings, and floors; enclosed pool area walls. Commercial examples: Continuous use steam shower/steam room walls and ceilings, enclosed pool areas, natatoriums, gang showers.

Res5 and Com5 High temperature air/water 125F

Tile surfaces frequently subjected to water or vapor equal to or greater than 125F

Residential examples: furnace and boiler areas Commercial examples: Commercial saunas, furnace and boiler areas, and some commercial kitchens

Res6 and Com6: Exteriors

Tile surfaces exposed to exterior conditions. When designing such installations, consider local climate and conditions including temperature and temperature fluctuations, humidity and humidity fluctuations, and freeze/thaw cycling. Residential examples: Exterior walls, balconies, decks Commercial examples: Exterior walls, balconies, decks.

Limitations of Classification System

Use and maintenance by owner may exceed system capacity Owner and design professional responsible for selecting appropriate method Tile contractor not responsible for moisture exposure exceeding methods limitations

Wet Area Guidelines

Inclusion of a drain w/waterproofing sloped to drain Shower pan membranes
Open weep holes Complete wrapping of curb Integrity of folded (not cut) in-corners Vapor retarder membrane overlap

Thickness and cure time of liquidapplied and trowel-applied bonded waterproof membranes

Wet Area Guidelines

Relative to the amount constructed, Nothing fails more often than shower pans (well, except steam showers) Grouted to tub
No seam overlap

Greenboard and Mastic

Plugged weep holes

Nails in curb

The duplication of tile methods to create stone methods unearthed inconsistencies, unclear cross-referencing, and unclear recommendations

Editorial Overhaul
Language standardized Language placement standardized to clarify responsibility Cross references eliminated Clarification of recommendations Are upgraded materials needed? Are upgraded materials included?

Improvements to Existing Categories

Requirements and Preparation by Other Trades improved to better indicate tile specification and installation versus specification and installation of other materials Notes, previously at bottom of pagenot clear if language was mandatory

Improvements to Existing Categories

Recommended Uses and Limitations updated for relevancy to real-world considerations
Utilize mortar bed or thin-bed attributes? On-ground and/or above-ground?

Above-ground methods separated to highlight important differences

Minimum performance mortar
ANSI A118.1 or ISO C1 for on-ground installations ANSI A118.4 or ISO C2S1 for above-ground installations

Movement joints
Every 20 to 25 for on-ground Every 8 to 12 for above-ground

Above-Ground Cautions
Limitations: Requires additional consideration by design professional to accommodate movement and/or deflection. Setting materials with improved bond strength and deformability are required. Requirements: Above-ground installations are inherently more susceptible to vibration and deflection. Grout and mortar manufacturer to warrant suitability of installation materials.

Above-ground Cautions
Preparation by Other Trades: When concentrated loads (scissor lifts, pallet jacks, automobiles, forklifts, etc.) will be used on an above-ground tile floor, the engineer and/or specifier shall specify a substrate to accommodate the concentrated loads. Owner/specifier is responsible for protecting the tilework from damage, including allowing sufficient time for installed materials to cure properly.

Improvements to Existing Categories

Materials section now indicates if minimum performance mortar must be upgraded to accommodate porcelain, membranes, etc.

Improvements to Existing Categories

Multiple options exist for membranes, mortars, grouts, and other materials and MUST BE CLEARLY SPECIFIED to be included. If not specifically indicated, optional materials are not included and mortar/grout choice defaults to minimum performance specification indicated. Consider each system component and intended use to determine minimum requirements and specify options.

New Categories
Environmental Classifications Typical Weight of Tile Installation Service Rating
Rating from Floor Tiling Installation Guide

Membrane Options

Optional Membranes
Optional crack isolation or waterproof membrane previously mentioned in almost all methods
No mention that better mortar might be needed No mention of possible affect on floor service rating No mention of changed suitability

Membrane Options
New category created to clarify types of membranes that may be used When glass tile is used, check with glass tile manufacturer for membrane options Cautions user to check with membrane manufacturer for changes of method suitability
Exterior, moisture vapor transmission, chemical resistance, above-ground use, etc.

New Methods and Significant Changes to Existing Methods

New wall method: W248

Glass-mat water-resistant gypsum backer board Walls in dry areas, including tubs with no shower head

New Floor Method: F250 Stone

Unique to stone For using backer board over a wood substrate Two layers of structural wood panels required due to discontinuity at seams in subfloor
Single layer permitted for mortar bed

New Pool Method: P602

For tanks that need to be waterproofed Cementitious waterproofing applied Mortar bed bonded to waterproofing

F125 Tile: Soft Materials Caution

Tiles that do not meet the breaking strength requirement of ANSI A137.1, such as Saltillo tiles, can be subject to breakage from strain induced by membrane movement or deflection over softer, compressible membrane material. Consult membrane and tile manufacturers Modified testing can be performed

F125 Stone: Soft Materials Caution

Stone tiles with reduced flexural strength, or natural planes of separation within the stone fabric may be vulnerable to breakage either due to elongation strain of the membrane or deflection over softer, compressible membrane materials. Consult membrane manufacturer and stone supplier Modified testing can be performed

EJ171: Movement Joints

EJ171: Movement Joints

all expansion, control, construction, cold, sawcut, isolation, contraction, and seismic joints in the structure should continue through the tilework, including such joints at vertical surfaces. If proprietary crack isolation membrane is specified over saw cut joints to relocate a movement joint, contrary to EJ-171, the tile contractor is not responsible for cracking in grout joints or tile where tile has been installed over any such relocated movement joints, provided the tile, membrane, and other materials are installed correctly;

EJ171: Movement Joints

Where tile pattern falls diagonally across a saw-cut joint, relocation of the movement joint is specifically not recommended because of the reduced performance of the sealant when used in a saw tooth or other non-linear fashion.

Steam Shower Revisions

SR613 concrete/masonry SR614 wood/metal framed walls

Steam shower improvements

Duration of use as a steam room or steam shower as determined by membrane manufacturer; lower membrane water vapor permeance decreases water vapor transmission Bonded waterproof membrane (sheet, liquid, and trowelon) must be continuous and must adequately limit vapor transmission into adjacent spaces and building materials, according to intended duration of use as a steam room or steam shower. Specify adequate insulation on walls and ceilings to reduce condensation.

Steam shower improvements

Specifier shall indicate how waterproofing and vapor retarding is to be achieved, including details for membrane penetrations such as penetrations for plumbing, lighting fixtures, etc. Specifier shall also indicate where and how to waterproof curbs and jambs and where membrane terminates. Seal all membrane penetrations with appropriate sealant according to membrane manufacturers requirements.

Steam Shower Improvements

Use of softened water in steam showers and steam rooms helps reduce grout and tile staining due to iron and/or hard water. Such stains may require harsh chemicals for removal. Select products suitable for water type and maintenance practices that will be used. Standard grouts will need to be periodically maintained over the life of the steam shower. Steam unit design must take into consideration the affect of moisture vapor transmission (MVT) on opposite side of steam unit walls. MVT can cause efflorescence and can affect paints and other adhered finishes.

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Local, regional, or national availability Residential or commercial Number of certified installers Individual certified installers also listed alphabetically for consumer cross referencing

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