TECHNICAL MANUAL FLOOR/WALL APPLICATION by MANUSPONG MUSIKARAYAKUL

TECHNICAL MANUAL

FLOOR/WALL APPLICATION

TECHNICAL MANUAL WALL/FLOOR APPLICATION

INDEX INTRODUCTION Product Specification Product Features Packaging Details Handling Handling equipment

INSPECTION Pattern and Joint laying Measuring and Inspection

FABRICATION Cutting Cut-out recomendation

INSTALLATION Preparing to the structure Install on Wall/Floor recommendation Quality control Cleaning and Maintenance Disclaimer

INTRODUCTION

GRANDE COLLECTION SIZE AND THICKNESS The GRANDE Collection by COTTO is an extralarge porcelain slab produced in new format up to 160×320 and 120×240 with 6 mm. thickness. Its superior size extends possibilities and flexibility in architectural application from floor and wall covering to countertops and external cladding.

160 cm

120 cm

SIZE ( length x width )

320 cm

240 cm

INTRODUCTION

x x

COLLECTION

SIZE AND THICKNESS 320 cm

160 cm

Top view (Lenght and Width)

BALZA Taking an inspiration from a rock-hard cliff, Balza represents borderless freedom and adventure of life in nature. Its monochromatic colors reflect a solitude and durability of a steep rock to withstand any natural impacts. This series of fine porcelain stoneware was created by harmoniously fusing a natural pattern of natural-cut granites. Its surface recalls the flamed natural stone slap which delivers delicate movement and sense of touch to all ambiences. Balza is a prime series designed for all areas, from interior to exterior, of modern architecture.

BIANCHEZZA A charm of marble has always been irresistible in a human history. It is a symbol of class, luxury, and purity in every architecture and interior design. This new mar ble collection of COT TO Italia is dedicated to an eternal beauty of white marbles, the most cherished and finest of its kind.

CLASSICI DI REX

I Classici di Rex is the resu capable of stamping a surroundings; they adapt astonishing solutions and natural inclination for bea

INTRODUCTION

x x

COLLECTION

BIANCHI DI REX

SELECTION OAK

ult of a feisty creative energy, decisive character on the t to architectural spaces with contrasts that underline their auty.

Made of coloured body porcelain stoneware 6 mm thick, with a glossy finish, this series opens a new chapter in the Rex line of products dedicated to natural materials: Having presented tiles inspired by wood, leather and stone, the Rex line now turns its attention to marble. Among the many existing varieties of marble, the most precious and soughtafter are the ones that are predominantly: white, in Italian bianco. The line includes three shades of white that represent light-coloured marbles and can make any room more exclusive and enveloping.

Taking its inspiration from oak wood, this has a soft, velvety texture and comes in two colours, selected with high-class precision to remind us of the light at mospheres of the sea and the warm colours of uncontaminated forests, where natureâ&#x20AC;&#x2122;s imperfections turn into a perfect harmony of tones and shades.Amber Rex has chosen a new style: the surface, strongly reminiscent of the natural world and bringing with it a wealth of delightful features, has been selected to blend into spaces and objects from past times mixed with new suggestions for architecture and furnishings. Relaxing simplicity and an essential aesthetic quality are able to create a dialogue with the atmospheres of the home and the charms of nature.

INTRODUCTION

SPECIFICATION

INTRODUCTION

SPECIFICATION

INTRODUCTION

PRODUCT FEATURES

COTTO Grande collection is porcelain slabs made from naturalmaterials such as feldspar, silica and clay. Thanks to its state-of-the-art CONTINUS+Technology, COTTO Grand collection offers superior properties for numerous functions and usages such as kitchen countertops, floor and wall coverings and facade cladding.

Technical features:

INTRODUCTION

PACKAGING DETAILS

PACKAGING AND TRASPORTATION SYSTEMS for any quantity and optimisation of spaces VERTICAL PALLET [A-FRAME] TRUCK

CONTAINER

Single lane handling

Insert forks in the short side

Anchor the loading using specific safety device

Fit special load isolation systems (LIS) Unload the good using specific belt anchorage systems

HORIZONTAL PALLET [CRATES] TRUCK

CONTAINER

Single lane handling

Max overlaping of 5 crates

Insert forks in hte long side

Anchor the loading using specific safety device

INTRODUCTION

PACKAGING DETAILS

A-FRAME

120 × 240 cm

160 × 320 cm

(thickness 6 mm)

(thickness 12 mm)

126,72

225,28

112,64

Total weight / A-frame (kg)

2.010

3.496

A-frame width (cm)

250

330

A-frame depth (side to pitchfork)

A-frame hight (cm)

160

199,6

slab weight (kg/pz)

41,7

74,14

148,28

A-frame weight (kg/pz)

162,6

217,5

217.5

max18

M2 / A-frame PZ / A-frame

How many A-frame in a truck ? How many A-frame for a 20’ CTNR ? How many A-frame for a 40’ CTNR ?

max20

INTRODUCTION

x x

PACKAGING DETAILS

CRATES

120 × 240 cm

160 × 320 cm

(thickness 6 mm)

M2 / crate

57,60

71,68

35,84

PZ / crate

Total weight / crate (kg)

965

1.178

Crate width (side to pitchfork) cm

265

345

Depth crate (cm)

136

175

Crate hight (cm)

40,2

37,2

overlaping in storage

max9

max10

overlaping in truck transport

max4

max5

How many crates in a truck ?

max20

max15

How many crates for a 40’ CTNR ?

max10

max6

How many crates for a 20’ CTNR ?

max20

max18

(thickness 12 mm)

INTRODUCTION

HANDLING The containers loading operations can be carried from the ground or by an appropriately sized ramp. In case of loading from the ground, it is necessary to: Pick up the A-frame from the forecourt and place it on the container floor. Proceed at the wheel locking of the vehicle putting specific wedges under the wheels (sudden removals of the vehicle are avoided). Always conduct a brief inspection to the container floor. Note. According to the A-Frame dimensions and according to the forklift used, the extension of the forks can be important to lift up the packaging properly.

COTTO Grande is extra Large format slabs arrive in oversized crates, which require specific handling equipment. To prevent damage from occurring during forklift operation, specific fork size must be used. For example, to handle a create of 160 × 320 cm tiles from the side, 122 cm/44” long forks are recommended. To hadle the same crate from the narrow end requires fork that are at least 213 cm/84” long. Lifting multiple crates with longer forks may require forklifts with a greater lift capacity. Specialized tools and equipment are currently available for the handling and installation of large porcelain surface. Innovative trowels with unique notch configurations can help increase the consistency of the mortar coverage on the b ack of the tile.

INTRODUCTION

HANDLING COTTO Grande collection slabs must be handled, loaded, unloadedand transported by a forklift,gantry crane or professional lifting machines.n every case of handling and transport, the slabs should be balanced considering its center of gravity to prevent possible damages or slab breakages

LOADING A-FRAMES ON CTRS TO 160 X 320 CONTAINER 20’ BOX SIZE

WEIGHT

EXTERIOR LENGTH: 6.059 MM

UNLADEN WEIGHT (TARE): 2.050 – 2.650 KG

INTERNAL LENGTH: 5.860 MM

MAXIMUM LADEN WEIGHT: 18.270 – 27.980 KG

EXTERNAL WIDTH: 2.438 MM INTERNAL WIDTH: 2.310 MM EXTERNAL HEIGHT: 2.591 MM INTERNAL HEIGHT: 2.360 MM REAR OPENING WIDTH: 2.280 MM REAR OPENING HEIGHT: 2.270 MM INTERNAL VOLUME OF LOADING: 32-33,9 M3

LOADING CRATES TO 160×320 - TRUCKS

Load / unload the vehicle from the ground using standard forklifts: - 30 quintals capacity - 160 cm Fork length Load the crates into single line or overlap them (to a maximum of 5 crates), handling must be individual. It’s necessary to provide belt safety devices (anchorage by ropes, jute straps, nylon straps with stretcher).

INTRODUCTION

HANDLING

Moving slabs for the pallet

Moving slabs by using suction cup(15mm), or Free-Move device

Place the suction cup on the surface. It is recommended to use at least 4 suctioncups for 4 people to move a slab. In lifting process, assign twopersons to push the slab from the back (It requires 4 people to move slabs with Free-Move device) Step 1: Lift a slab and lean on theedge of pallet to prevent breakage Step 2: Rotate slab to vertical orientation

INTRODUCTION

HANDLING

Handling Equipment

A-Frame to free move

Handeling device to free move

Caution: 1. before handling slabs, please inspect conditions of machines to ensure their workability and make sure that weight of slabs do not exceed weight limit of machines. 2. C l a m p s c a n b e u s e d f o r p r o p e r h a n d l i n g , while canvas slings are more suitable for handling multiple slabs at the same time. Given the hardness and sharpness of the material, there may be sharp edges on the slabs. Therefore, it is highly recommended to cover the canvas slings with protective covers to prevent possible accidents or damages to slabs. Please consult the sling manufacturers for details of proper covers.

Handling with Easy Move

Double Suction Cup 115 MM

3. Vacuum clamp is suitable only for slabs with flat surfaces. Using vacuum clamp with other rough surfaces may cause dangers in handling process.

INSPECTION

INSPECTION AND COLLECTION DATA ON SITE

PATTERN AND JOINT LAYING

Even COTTO Grande collection is available in large slab, some panel may need two or more slabs to complete the work. As each slab of COTTO is not exactly indentical but different in details, it is recommended that each slab is laid precisely to ensure beautiful vein coordination and patterns

Laying pattern and the joints between the panel in the same plane

INSPECTION AND COLLECTION DATA ON SITE

MEASURING AND INSPECTION THE STRUCTURE

Measuring equipment - Self-leveling line laser - Plumb and Hose water meter

Inspect and make sure that walls are flat and perfectly angled

Inspect quality of surface, and make sure that there is no crack

Measure slope of working area

FABRICATION

CUT RECOMMENDATION

Tools and equipment for in fabrication process

- Cutting desk reinforced by MDF board (12 mm thickness)

- Cutting tools (diamond cutter)

- Cordless Sidewinder Circular Saws

- Cutting Handheld Tools

FABRICATION

CUT RECOMMENDATION

Handle slab with handling equipment

Measure and mark cutting line with pencil

Cut the slab by pushing the cutter along marked cutting line from the edge to the other edge. Try to cut with only one attempt to prevent breakage.

After cutting with the cutter, place the cracker tools at the middle point of cutting line, then tighten the screw until you hear the crack, then split the slab gently. It is recommended to assign at least two people to work in this process.

FABRICATION

CUT RECOMMENDATION

Cutting rectangular hole

Mark cutting line of rectangular hole with pencil

Use electric drill and hole saw (1 inch) to drill at four corners

Use cutting machine to cut along the line, but leaving the corner to stay intact.

Smoothen the edge for best quality of finished work

FABRICATION

CUT RECOMMENDATION

Manual machining Warnings During any type of manual processing the workpiece should be adequately supported with a flat resting base in good condition, preferably made of wood. For any type of machining process always use high water flow rates.

Suggested sequence The sequences described are subject to possible variations due to ongoing research into improvements in product fabrication. We recommend contacting your dealer or the COTTO Grande technical service department for any details you may require.

INSTALLATION

PRE-INSTALLATION AND PREPARATION

In case of wall installation, please follow this instruction

For wall with 0 â&#x20AC;&#x201C; 3.2 m. height, it is recommended to use cement glue with sandwich technique

For wall taller than 3.2 m, it is recommended to install with mechanical cladding system

Measuring Make sure that working area is in perfect condition before installation - Cleanliness of surface - Flatness of surface - Strength of surface

INSTALLATION

PRE-INSTALLATION AND PREPARATION

Mixing cement glue

Mix 4.5 â&#x20AC;&#x201C; 5.0 lire of water with 20 kg. of cement glue in the bucket. Mix until fused harmoniously by using electric stirrer (150 rpm speed) and leave 5-10 minutes before start applying the glue

Applying cement glue Applying cement glue on the back of tiles Use trowel (3mm) to spread cement glue with 45 degree angle. Make sure the cementglue fully covers the back of tiles.

Applying cement glue on floor/wall Use trowel to spread cement glue on working area and install tiles within 20-30 minutes to prevent over setting. Use trowel (15 mm) to spread cement glue with 45 degree angle to fully cover working area.

INSTALLATION

FLOOR AND WALL INSTALLATION

Moving slabs for installation

Use a suction cup in moving process to facilitate angle adjustment

Make sure that surface of slab is flat

Handle slab by holding on horizontal end, and rotate slabs at 30 degree before installing

Firming slab installation

Use rubber hammer or vibrator to firm installation by knocking gently on slabs. This helps spread cement glue consistently. It is recommended to use white rubber hammer to avoid leaving stain on the surface

INSTALLATION

FLOOR AND WALL INSTALLATION

Leveling tools

Attach wedge on the base manually

Gently tighten wedge with the base until firm

Make sure that surface of two slabs next to each other are flat before continuing installation

Removing the wedges

Leave glue cement at least 24 hours to set firmly Use rubber hammer to knock off the wedgeout of the base. The wedge can be reused. Remove grouting and clean finished work

INSTALLATION

CLEANING AND MAINTENANCE

Cleaning after installation

Cleaning after installation is mainly to remove stain of cement glue, grout, and dirt left after installation to ensure the best quality work

It is recommended to use Fila Deterdek solution (mixed with water in ratio 1:5)

Apply diluted solution on the surface, and leave 5-10 minute before rubbing gently with soft cloth or microfiber cloth

Do not use metal brush of cleaning tools with hard surface to protect the surface

INSTALLATION

CLEANING AND MAINTENANCE

Maintenance

Clean the surface before grouting

Apply diluted Deterdek solution and clean with soft cloth

Mix grout and apply at joints of tiles (consult details on packaging for mixing ratio and expiry date)

INSTALLATION

CLEANING AND MAINTENANCE

COTTO Grande ars non porous [due to their high quality raw materials, stringent production parameters and state of the are technology], hence any dust or deposited waste cannot penetrate the surface. But its is necessary to remove the from the surface. For most cases only a damp cloth is sufficient for cleaning. Regular cleaning highlights the aesthetic features of the surface gives it exceptional shine. For highly aggressive cleaning caused by some common food and substances follow the table below.

TYPE OF STAIN

CHEMICAL PRODUCT

EXAMPLE

Cement

Acid

Hydrolic acid

Oil

Solvent

Ammonia

Coffee

Alkaline - Solvent

Rubber

Solvent

Ammonia or Bleach

Alcohol

Rust

Acid

Hydrolic acid

Ink

Oxidant - Solvent

Alcohol

Candle wax

Solvent

Alcohol

INSTALLATION

DISCLAIMER The aim of this manual is to offer some helpful guidelines and suggestions about machining, laying and maintaining the COTTO Grande slabs. Information contained herein reflects the state of art of the Producerâ&#x20AC;&#x2122;s technical, scientific and operational knowledge at the time of its publishing; it is therefore highly advised to keep up with the latest version available on the site www.geoluxe.com in the download area. However, since it is a sintered ceramic material, we highly recommend the user not to restrict himself to the indications herein but to consult the wide technical, scientific and operational literature available on this subject, as well as to refer to professionals for the various machining and laying phases of ceramic products. Since no complaint will be accepted on installed materials with defects existing at delivery, it is advisable to check the color shade, thickness and surface finish at delivery. In case of complaints it is advisable to contact COTTO technical team, addressing your e-mail to cotto@scg.co.th ; our technicians will be at your disposal.

Thai Ceramic Co., Ltd. 1 Siam Cement Rd., Bangsue, Bangkok 10800, Thailand. www.cotto.co.th/cottogrande