TATA PROJECTS LIMITED, HYDERABAD

PROJECT: CIVIL WORKS FOR BLAST FURNACE I – PHASE 1B

METHOD STATEMENT FOR FLOORING WORK

DOCUMENT NO : CS - 340012 – MS –FLOORING- 025

CLIENT

R0 10.10.2015 Issued for Information / Approval TPL TPL

Rev Issue Date Description Prepared by Reviewed Approved by

JINDAL STEEL AND POWER LIMITED

CONSTRUCTION AGENCY

TATA PROJECTS LIMITED

CONTENTS

SL.NO DESCRIPTION PAGE NO

Page 1 of 7
 TATA PROJECTS LIMITED, HYDERABAD
PROJECT: CIVIL WORKS FOR BLAST FURNACE I – PHASE 1B

1 PURPOSE 3-3
2 SCOPE 3-3
3 REFERENCE DOCUMENTS 3-3
4 MATERIAL AND PROCEDURE 3-7
5 SAFETY 7-7
6 DOCUMENTATION 7-7

1. PURPOSE

The purpose of this procedure is to provide methodology of various activities involved in

different types of flooring work.

Page 2 of 7
 TATA PROJECTS LIMITED, HYDERABAD
PROJECT: CIVIL WORKS FOR BLAST FURNACE I – PHASE 1B

2. SCOPE

The procedure covers laying and finishing of flooring of various typed mentioned as follows.

2.1. Kota stone /Marble/Granite

2.3. Tile work (Ceramic/Vitrified)
2.3. Acid resistant tiling work

3. REFERENCE DOCUMENTS.

3.1. Approved Drawings.

3.1. Customer’s Specification No: JSPLA-PH2-GS-C-01 (Need to change as per project)

4. MATERIAL AND PROCEDURE

4.1. Kota stone/Marble/Granite

4.1.1 Stone flooring consists of 20 mm to 25 mm thick marble/kota/granite slabs laid over 20 mm

thick base of cement coarse sand mortar of 1:3 and jointed with white cement slurry mixed
with pigment to match the shade of stone.  The stones/slabs used in flooring or dado are
cut according to the size and shapes given in drawing or to suit site dimension of the room
and desired pattern. All angles and edges of marble slabs are true and square and are free
from chipping. The surface is true and plain.

4.1.2. The overall thickness of stone slabs on hardened concrete base shall be 50mm (including
bedding) as specified in the approved drawings.

4.1.3. Material required:

 Kota stone/Marble/Granite Stone

 Coarse Sand
 Ordinary Cement
 White Cement
 Pigment
 Polishing Material

The stone shall be hard, dense, sound, and homogeneous in texture, free from cracks , decay,
weathering and flakes. All angles and edges of the slabs shall be true and square, free from
any chipping giving a plane surface.

4.1.4. Bedding:
 The surface of the base concrete shall be thoroughly scraped to remove dirt, loose particles
and laitance by scrubbing with a wire brush. The surface shall then be thoroughly cleaned
and well wetted but without forming any water pools on the surface and any excess water
shall be removed.
 Screed pads shall be set up to indicate finished floor level on the clean damp surface of the
base concrete and setting mortar bed shall then be evenly spread. The proportion of setting
bed shall be one (1) part of cement and three (3) part of coarse sand.

 Slope shall be maintained as per the drawing.

Page 3 of 7
 TATA PROJECTS LIMITED, HYDERABAD
PROJECT: CIVIL WORKS FOR BLAST FURNACE I – PHASE 1B

 The thickness of bedding should not be less than 12 mm in any place.

 The top surface of mortar (bedding) should be leveled correctly by adding fresh mortar at
hollows if any.

4.1.5. Fixing:

 When the bedding mortar acquires sufficient hardness to provide a fairly rigid cushion for
the tiles/slabs, neat cement slurry shall be spread at the rate of 4.4 kg per sq. meter for
honey like consistency shall be spread over an area at a time, as would accommodate about
10 stone slabs.

 The stone slabs shall then be fixed in this grout one at a time and gently tamped with a
wooden mallet to set properly on the bedding and in level with the adjoining stone slabs.

 Care should be taken to match the grains of slabs.  All stone slabs should be laid in same
manner.

 The joints between slabs shall be straight and shall not exceed 1.5 mm width. The top
surface of the slabs shall be laid true to plane with levels and/or slopes.

 After the slabs have been laid, the surplus cement grout that may have come out of the
joints, shall be cleaned off. In areas adjoining walls, the slabs shall extend about 10 mm
inside the plaster, skirting or dado as the case may be.

 The day after the stone slabs have been fixed, the joints shall be re-filled with cement
paste or grout mixed with pigment to match the shade of the slabs.

 Before the joints are filled, they shall be cleaned with wire brush or with the point of a
trowel and any loose cement, dirt or dust in the joints shall be removed.

4.1.6. Polishing and Finishing

 The grinding may be done either by hand or by machine.
  Manual grinding should be done after two days of laying of marble flooring
 Machine grinding should commence 3-4 days after laying marble stone flooring

First Grinding

 The grinding should be done by machine with grit No. 60.

 The water should be used profusely during grinding.
 After grinding the surface should thoroughly be washed to remove all grinding mud.

Second Grinding

 The second grinding is done with machine fitted with fine grit blocks No120. The surface is
again washed cleanly and is repaired if required.

Final Grinding

 The final grinding with machine fitted with finest grade grit blocks No. 320 should be
carried out the day after second grinding.
Page 4 of 7
 TATA PROJECTS LIMITED, HYDERABAD
PROJECT: CIVIL WORKS FOR BLAST FURNACE I – PHASE 1B

  The grinding should be done to get the surface even, smooth without any pinholes.  

  Care should be taken during final grinding that foreign matter, particles of sand etc.
Scratch the surface shall not be done at any case.

 After final grinding, whether by machine or by hand, the surface should be washed clean.   

 The water is then sprinkled and the surface is rubbed hard with felt or pad of woolen rags.

  Next day the floor should be wiped with a moist rag and be dried with a soft cloth and be
finished cleanly. 

 The floor should then be covered with oil free saw dust which is removed after completion
of all construction work, such as painting, distempering, electrical work, plumbing, joinery
work etc.  

 After occupying area the floor should be washed cleanly with dilute oxalic acid solution,
shall be dried and rubbed with clean cotton waste.

 In case wax polished surface is desired, wax polish is applied sparingly with soft cloth on
clean and dry surface.

 The surface should be rubbed thoroughly with clean cotton waste or a polishing machine
fitted with felt or jute bag bobs.

 Any surplus wax should be mopped up and rubbing is continued until the floor ceases to be
sticky.

4.1.7 Precautions
 Care should be taken that the floor is not left slippery.

 Neat cement should be applied on joints.

 The joints should be in straight lines and not more than 1 mm wide.

 Fill in the joints with cement-pigment paste of matching color after one day.

 Minimum seven days curing is recommended after stone slabs are fixed as inadequate
curing leads to stone slab de-bonding from mortar

4.2. TILE WORK (CERAMIC / VETRIFIED)

4.2.1. Tiles shall be of best quality from an approved manufacturer. The tiles shall be flat, true to
shape and free from flaws such as crazing, pinholes, specs or wets. Edges and underside of
the tiles shall be free from glaze and shall have ribs or indentations for a better anchorage
with the bedding mortar.

4.2.2. All the inside walls, ceiling and outside walls shall be plastered and door frames and windows
fixed in position before proceeding to tiling work. Before tiling work is started, all points of
level for the finished tile surface shall be marked out. Wherever slopes in finished floor are
Page 5 of 7
 TATA PROJECTS LIMITED, HYDERABAD
PROJECT: CIVIL WORKS FOR BLAST FURNACE I – PHASE 1B

desired, points and level and outlets shall be correctly marked and outlet openings made
beforehand.

4.2.3 The cement mortar (1:3), as per JSPL specification, clause no: 1.7.4 of SECTION 0 shall be
provided as bedding for the tiles over the base concrete. The quantity of water added to
the mortar shall be just adequate to obtain the workability of lying. The surface of bedding
shall be left rough to provide a good bond for the tiles.

4.2.4. Bedding: -

 The surface of the sub-floor shall be thoroughly cleaned of dirt, loose particles and laitance
(in case of cement slabs) by scrubbing with a wire brush.

 The surface shall then be thoroughly cleaned and well wetted but without forming any
water pools on the surface.

 Screed pads shall be set up to indicate required levels on the clean damp surface of the
sub-floor and cement sand mortar shall then be evenly spread.

 The mortar for the setting bed for tiles shall be consisting of cement and coarse sand in
the proportion of 1:3.

 Slope shall be maintained as per drawing.

4.2.5. Fixing: -
 When the bedding mortar acquires sufficient hardness to provide a fairly rigid cushion for
the tiles, neat cement slurry of honey like consistency shall be spread over an area at a time,
as would accommodate about 20 tiles.

 The tiles shall then be fixed in this grout one at a time and gently tamped with a wooden
mallet to set properly on the bedding at the level of the adjoining tiles.

 In areas adjoining walls, the tiles shall extend about 10 mm inside the plaster, skirting or
dado as the case may be. The joints between tiles shall be straight and shall not exceed 1.5
mm in width.

 After fixing the tiles, the joints shall be refilled on the following day with cement paste or
grout of the same shade as that of the matrix of the tile.

 Before the joints are filled, they shall be cleaned with wire brush or with the point of a
trowel and any loose cement, dirt or dust in the joints shall be removed.

4.3. Acid resistant tiling work.

4.3.1. Approved material shall be used.

4.3.2. Bedding mortar: - Endura gold star(Industrial mortar).

4.3.3. Joint Filler: - Endura Epoxy mortar

5. SAFETY

Page 6 of 7
 TATA PROJECTS LIMITED, HYDERABAD
PROJECT: CIVIL WORKS FOR BLAST FURNACE I – PHASE 1B

5.1. All necessary PPEs shall be available with all workmen.

5.2. Only trained & experienced workmen shall be deployed for this job.
5.3. Provide sufficient safety protection (like warning signs, barricading etc) around t h e
working zone.

6. DOCUMENTATION

6.1. Check list is attached separately to make documentation of the work.

Page 7 of 7