Engineered Terrazzo

Construction Process and Winter Considerations for Stone Installation

1. Grouting Process:

First Layer of Grouting:
After the first injection of 15cm of grouting, allow it to set for 1-2 hours to ensure the initial setting of the mortar. During this period, check for any movement in the material.

Second Layer of Grouting:
Once the initial setting has occurred, proceed with the second layer of grouting. This layer should be 20-30cm in height. Continue the grouting process after the mortar has begun to set.

Third Layer of Grouting:
The third and final layer should be applied until the grouting is 5cm below the top of the board. Ensure the consistency of the grouting process across all layers for an even and secure installation.

2. Wiping the Seams:

• After all stone slabs have been installed, carefully remove any traces of gypsum or residual slurry from the surface.
• Use a linen cloth to scrub the slabs clean.
• Prepare a color paste caulking that matches the color of the slate and apply it to the seams. This ensures that the edges are:
  • Dense
  • Uniform
  • Clean
  • Consistent in color, creating a polished and seamless finish.

3. Column Veneer Installation:

• For columns, install cylindrical marble, prefabricated engineered terrazzo, or polished granite following the same procedures as the wall inlay method. This includes:
  • Elastic threading
  • Drilling holes
  • Tying steel bars
• Wooden Square Nails:
  Before grouting, use wooden square nails to secure the marble or terrazzo slabs in place. These should be positioned on both sides of the stone to prevent swelling during the grouting process. Use convex-shaped wooden clamps to hold the slabs tightly, ensuring they stay in position.

4. Winter Construction Considerations:

• Mortar Insulation:
  The temperature of the grouting mortar should not fall below 5°C. Ensure that the mortar is insulated to maintain an optimal working temperature.

• Protection from Freezing:
  Mortar should not freeze during its initial hardening stage. When working outdoors in cold weather (temperatures lower than 5°C), mix additives into the mortar to reduce its freezing point. The exact amount of additives should be determined through experimentation.

• Thawing of Walls:
  Walls constructed using the freezing method must not be worked on until they are fully thawed to avoid any adverse effects on the construction process.

• Heating for Winter Construction:
  During winter, it is recommended to use heating to assist with the curing and drying process. Options include:

  • Hot air systems
  • Stoves with chimneys to speed up drying times.

• Ventilation:
  When using hot air, ensure that proper ventilation equipment is in place to remove excess moisture from the air.

  • Assign a dedicated person to monitor and manage the temperature control to ensure a consistent environment for the construction.

This approach ensures the durability and quality of the installation, regardless of seasonal challenges.