Panoramic Porcelain Surfaces Fabrication / Install Guide

FABRICATION & INSTALLATION GUIDE SECTION 1 INTRODUCTION

2 INTRODUCTION TO PANORAMIC PORCELAIN SURFACES

Daltile is proud to launch Panoramic Porcelain Surfaces™, a line of 6mm and 12mm porcelain slabs in sizes up to 10.5 feet by 5.3 feet. This new product line gives our customers an opportunity to bring to their projects the scale and style of natural stone slab with the benefits of porcelain tile.

Already a popular concept in the European market, large-format porcelain is fairly new to the US market. Given that it offers designers, architects and builders the stunning look of natural stone without the cost and maintenance issues, it is certain to become an ideal choice for projects both residential and commercial.

3 VERSATILITY BUILT-IN

Panoramic Porcelain Surfaces is a powerful new tool that allows designers to unleash creativity that was previously cost-or installation-prohibitive. They’re now free to create the spaces they’ve always envisioned without limits. Plus, not all stones are appropriate for all installation types, which gives limitations to coordinating colors. Porcelain slab offers coordinating wall, countertop and floor options that do not have installation limitations.

WHERE WE SEE IT WORKING

In commercial, we see PPS being used in hotels and office buildings where stone is typically used – especially in cases where architects and designers would like to use stone, but the budget wouldn’t allow it. In hospitality, Panoramic can be used to create seamless bathroom designs, high-impact amenity spaces, etc. Cost savings in both material and installation will make it an especially attractive option for large projects. In addition, tile-over-tile applications – especially in hotels – is a green cost savings, eliminating tear-out of existing tile. Other applications are exterior cladding both direct-adhered and porcelain-ventilated facades.

Residential applications include countertops, vanities, shower walls, tub surrounds, fireplaces, floors and feature walls. Homeowners seeking the look of stone without the hard work, maintenance and expense will find it a smart choice.

4 SECTION 2 HANDLING

5 When receiving Panoramic Porcelain Surfaces (PPS) in quantity for warehousing stock or for a project, you will need a forklift with 8-foot forks or 8-foot fork extensions. The panels will come packed on an A-frame. When offloading or loading A-frames, an Abaco glass lifter attached to a boom on a forklift or indoor crane is recommended. You should never attempt to lift or move porcelain panels with granite clamps!

6 If unpacking PPS off an A-frame, place a soft jaw clamp over the panels at one end to secure prior to removing factory banding/strapping. PPS slabs of 6mm thick weigh 2.92 lbs. per sq. ft. and panels of 12mm thick weigh 5.84 lbs. per sq. ft. The most common moving procedure for 6mm is two people equipped with the ETM grip or the ETM slide. With 12mm, you need at least three people equipped with the ETM grip. An additional option for handling 12mm, is using the ETM double slide with pump cups.

Identify destination and have protection in place prior to moving. It’s a good idea to use corner protectors. Purpose-built tools are available for proper handling of Panoramic Porcelain Surfaces. See Appendix B for full list of tools.

7 SECTION 3 TRANSPORT

8 If picking up Panoramic Porcelain Surfaces at supplier’s facility, use a suitably sized A-frame that offers cushioned/proper protection at all contact points. Use suitably sized vehicle to house and carry the A-frame. Always strap Panoramic slabs to the A-frame and the A-frame to the vehicle. Never clamp Panoramic slabs during transport, as damage/ breakage may result. Contractors can pick up PPS slabs at Daltile facilities as well as transport up to 30 pieces of 6mm slabs to the job site using the ETM Trailer Frame. For job site and shop movement, the ETM Transporter can store up to 16 pieces of 6mm, or 8 pieces of 12mm slabs. A-Frames are ideal for moving up to two slabs.

9 SECTION 4 FABRICATION

10 The most important part of fabricating/cutting PPS is a flat sturdy surface of supportive size. Tables designed for use with porcelain slabs are available.

For 6mm thickness, pre-application of ½” thick high-density foam backer board to support PPS is recommended prior to fabrication of sink holes or other features at countertops, for rigidity and strength during installation. With the backer preinstalled, the fabricated countertops can be installed over ¾” plywood set on top of cabinets.

For 12mm thickness, pre-application of ½” backer board is recommended to support PPS over ¾” plywood installed on cabinets. The backer board provides additional support for aprons and turndown edges. Panoramic Porcelain Surfaces should not be applied directly to plywood attached to cabinets.

6mm and 12mm Panoramic slabs can be installed directly over existing natural stone and other solid surface tops.

Standard cutting is easiest done by the score-and-break process for straight cuts. “L”, “U”, and dropout cuts first must have a hole drilled through the porcelain slab with a ³⁄16” diameter or larger porcelain stoneware drill bit at the beginning and end of each cut-line to relieve the pressure and prevent cracking.

11 UNDER-MOUNT SINKS How you fabricate porcelain panels for countertops with under-mount sinks depends on the style of sink:

• Square or rectangular – Miter a “turn down” piece at edges to achieve the look of natural stone thickness. • Radius or other shape – Cut hole, keeping back from template mark, and sand/grind/polish to template line.

A Top Zero under-mount sink has no flanged edge, so it offers the best finish on a porcelain countertop.

12 MITERING

Mitering is commonly performed when fabricating Panoramic Porcelain Surfaces for countertop use. But it's important to remember that the patterned design is only on the surface, so it's important to create a knifepoint cut at edges to be mitered.

Acrylic or epoxy can be used to bond miters. Miters must be filled completely in order to protect finished edge from chipping or breaking.

Use color kit and match accordingly. If bonding/filling mitered edge of veined material, mix one color to match veining and another color to match body. Fill accordingly. 13 SECTION 5 INSTALLATION

14 Large-format tile installation requires particular attention to proper substrate preparation, grout joint sizing, trowel selection, and mortar coverage. It is critical that large-format tile be installed on a level substrate. Additionally, there must be at least 90% mortar contact, and the tile should be installed in accordance per the grout joint recommendations of each tile series. Refer to the published installation instructions prepared by your preferred manufacturer of setting materials for optimal tools and setting methods to achieve your desired result.

For proper bonding, LHT mortar must be used in installing tiles with a dimensional length greater than 15 inches on any one side of the tile. Back buttering tiles of this nature in the installation process will also assure proper coverage for body. In countertop applications, the porcelain tiles should first be mounted to substrate prior to cutting, mitering, etc.

SEAMING

Seams can be installed using same process as natural stone tops, seam leveling tool, acrylic or epoxy for adherence. If backer board is used, make sure to bond backer board under porcelain at seam with proper adhesive.

15 KEYS TO SUCCESSFUL INSTALLATION

Vertical Wall • Handling both 6mm and 12mm • Accessories required for handling slab • Substrate and substrate preparation • Strict flatness requirements related to 6mm • Trowel-applied patching compound, waterproofing and crack isolation membranes • Selecting right installation product or project

Countertop • Handling both 6mm and 12mm • Standard tooling • Continuous rim porcelain blades only, not to exceed 5-inch diameter in hand-held tools. For larger shop saws, maximum 10-inch diameter. – Grinding Discs (refining and trimming edges) – Silicon Carbide and Felt Polishing pads – Epoxy w/color matching pigments – Standard Core Drill bits • Sinks – Under Mount, Over Mount and Flush • Substrate required • Seaming procedure for countertop • Mitered Edge Profiling – good training and education very important

INSTALLATION TIPS

• Installation of Daltile’s Panoramic Porcelain Surfaces is basically the same as all other large-format porcelain tile, for floor and wall applications. Using proper tools is a must for a successful handling and installation. • Important install notes –– Substrate must be within ⅛” variance in 10 feet. –– LHT mortar must be used with zipper notch type trowels. –– Back butter all tile for complete mortar coverage. –– Edge leveling device system must be used on all joints. –– De-airing with beating block on walls and walking on from center out on floors, to ensure complete mortar coverage • Handling –– Pick materials up with grip and suction cup, minimum two people. We are handling it ourselves. –– It’s big, it’s lightweight but it requires the right tools to handle it. Safety first. –– Equipment to help with transport, handling, cutting, fabrication, delivery and installation. –– European Tile Masters Tools – three tool packages available.

16 SECTION 6 ABOUT PANORAMIC PORCELAIN SURFACES™

17 BLANC

MARFIL

CALACATTA

STATUARIO

PRODUCT SPECS

Panoramic Porcelain Surfaces are grouped into two series, the Elemental Selection and the Industrial Selection in a total of eight colors with 11 finish and color options

• Elemental Selection Colors: –– Statuario (glossy or matte) –– Calacatta (glossy or matte) –– Marfil (glossy or matte) –– Blanc (matte finish only)

18 HEARTH SMOKE

STONEWALL COAL

VICKERY TAUPE

BELMONT TERRACE

• Industrial Selection Colors (all are matte finish): –– Belmont Terrace –– Vickery Taupe –– Stonewall Coal –– Hearth Smoke

19 Initial slab stocking sizes – Delivered on A-frames • 126” x 63” x 1/4” Rectified (160cm x 320cm x 6mm) – 147 lbs. • 127” x 64” x 1/2” Not Rectified (163cm x 324cm x 12mm) –– approximately 10.5’ by 5.3’ • 6mm thickness for wall/floor, 12mm for countertop

20 FLEXFIT™ CUSTOM CUT TO SIZE PROGRAM

FLEXFIT™ GUIDE CUSTOM CUT TO SIZE PROGRAM

STANDARD SIZES AVAILABLE*: (6mm or 12mm)

63" x 63" 31.50" x 126" 31.50" x 63"

15.75" x 63" 31.50" x 31.50" 15.75" x 31.50" 21" x 21"

*Custom sizes as well as modular sizes for pattern installations available. All requests subject to minimum order quantities & lead times. Contact us for details & pricing.

8 Stock Hub Stone Center Locations • Denver, Dallas, Atlanta, Miami, Chicago, New York, Anaheim, Santa Clara

21 SECTION 7 APPENDIX

22 APPENDIX A

STORAGE

Always store Panoramic Porcelain Surfaces in a vertical upright position. Never lay flat. The safest storage is placed on an A-frame and secured via strapping or clamped with a soft jaw clamp at each end of A-frame. If staging Panoramic slabs on a construction/ job site prior to installation, place in a secure location out of the way of construction traffic. If installing Panoramic slabs on a large and/or multiphase project, deliver only an amount that will be used in a short amount of time or for the phase you are currently working on. Do not store on active project sites for long periods of time. Leave stored in supplier’s warehouse or in an offsite secure location.

CARE AND MAINTENANCE

Unlike stone slabs, no special care is required for ensuring the longevity of Panoramic Porcelain Surfaces. The same products used for traditional porcelain tile can be used on PPS, including: • Fila Cleaning Solutions: www.filasolutions.com • Aquamix products: www.custombuildingproducts.com/products/aqua-mix.aspx • Hillyard Incorporated: www.hillyard.com

Household cleaners recommended for daily use: • Windex • Baking Soda • Ammonia • Lysol Gel with Magic Eraser for tough stains • Brasso gel with Magic Eraser for metallic stains or marks • All PH neutral cleaners

ACCESSORY PRODUCTS

Accessory Products: • Kerdi Board for countertop substrate: www.schluter.com • Wedi Board for backing to fabricate: www.wedicorp.com • Fix Top Adhesive for wood and other “tough to bond to” substrates: www.tenax4you.com • Bonding agents are acrylic and epoxy only for miters and repairs. Manufacturers: –– Epoxy – AKEMI www.akemi.de/en/ –– Acrylic – Chemical Concepts www.chemical-concepts.com • Top Zero Sinks: www.topzero.com • Abaco Clamp: www.abacomachines.com

RECOMMENDED PPS TOOL MANUFACTURERS

• European Tile Masters: www.europeantilemasters.com • Omega Diamond: www.omegadiamond.com 23 APPENDIX B

[email protected] PHONE:954-917-3599 FAX:954.917.3539

1. ETM-RAIL CUTTER 12’ (3 IN 1 – RAIL, RIP & CROSS) - 565858 Ø The most accurate & easy to use 2 piece cutter, includes adjustable brackets to transform it in to the Rip or Cross Cutter for repeated cuts Ø Extension Handle is designed to score the full width of tile with ease Ø Includes 3 built in tape measures to eliminate the need to mark the tile, 3 suction cups for secure attachment and the ETM-SNAP to snap tile after scoring

2. ETM-GRIP - 565853 Ø To unload, move, handle & back butter tile up to 1.6m x 3.2m x 12mm (63” x 126” x ½”) 3. ETM-EXPRESS CUTTER - 566597 Ø 12 fully adjustable suction cups designed for Ø Capable of cutting unlimited lengths smooth & rough tile surfaces Ø Slides on the edge of tile Ø Includes 8 adjustable handles Ø Ships completely assembled Ø Free standing frame on 4 casters Ø Built in measuring system

4. ETM-EZ BREAKER - 568409 Ø Designed to break very narrow pieces of tile up to 12mm thick (1/2”)

5. ETM-LIFT - 568419 Ø Designed to lift tile in conjunction with the ETM-G R I P. Ø Can be easily attached to Scissor Lift and other lift equipment Ø Telescopic arms are engineered to slide tile in to place

24 6. ETM-SLIDE - 565857 7. ETM-TRANSPORTER - 565854 Ø Designed to easily move & handle odd shaped tile Ø Fully adjustable cross bar to secure of various sizes tiles Ø Set includes 10 suction cups & 2 - 28” end sections Ø Light weight, easy to move, safely Ø Adjusts to multiple length configuration (6’ to 12’) transports up to 8 pieces of 6, 8, 10, or Ø Adjusts to multiple shape configuration (T,U & Z 12mm or 24 pieces of 3mm tile shapes)

8. ETM-SPINE - 566599 Ø To easily load and unload tile Ø Installing 1x1 and 1.5x1.5 meter tile 9. ETM-STEP - 568416 Ø Light weight frame with adjustable feet & dual casters for easy mobility Ø Top step designed to securely hold 2 buckets

10. ETM-APRON EDGE SUPPORT - # NEEDED Ø Designed to hold counter top apron in place for quick and accurate assembly Ø The 12 piece kit attaches to the ETM table

11. ETM-TABLE - 566596 Ø Two 72 x 39 tables (tables designed to be connected) Ø Unique clamping system which secures tile to table Ø Folding legs Ø Total width of 63” when included table extension is attached Ø Built in Power Strip Ø Designed to store other tools

25 12. ETM-TRAILER FRAME - # NEEDED 13. ETM-PLUNGE CUTTER - # NEEDED Ø Designed for porcelain panel/slab transportation Ø Design to cut sinkholes in porcelain, Ø Must be permanently attached to trailer chassis marble, granite, slate & quartz Ø The system will securely hold up to 30 pieces of 6mm Ø Extremely accurate easy to set up thick 1600 mm (63") wide x 3200 mm (126") long Ø Includes quick release water system porcelain panel/slab tiles Ø The guide rail attaches to the surface Ø 4 quick locking arms while loading tile with 4 special suction cups Ø 2 upright arms to secure tile Ø The rails & suction cups will hold sink hole cut out in place

14. ETM-A-FRAME - 565855 15. ETM-SAWHORSE SET - 568405 Ø Designed to display and store full size tiles Ø Designed to support ETM-GRIP while Ø Ideal for showrooms and job sites spreading thinset Ø Easy height adjustment Ø Works well with ETM-TABLE for extra support of tiles

16. ETM-LEAN - 568404 17. SIGMA KERA-EDGE KIT - 566587 Ø Designed for use in hard to reach Ø For beveling & bullnosing tile places without stepping in thinset

18. ETM-47° MITER SAW KIT 19. SIGMA KERA-MITER KIT 20. SIGMA KERA-FLEX KIT 568443 568407 566586 Ø Designed for one pass miter cuts Ø For face mitering Ø For plunge & L cuts Ø Used for tile thickness up to 2cm Ø One pass mitering with backer ( ½” in thickness) board glued to tile Ø Includes quick release water system

26 SIGMA KERA CUT 23. SIGMA TILE CUTTERS 21. 8E2-10’ - 563807 22. 8C2-5’ - 563806 Ø Designed for cutting: porcelain, pavers, Ø Accurate & easy to use tile cutter quarry Ø Glass, mosaic & certain types of marble & granite Ø Cutter range from 14” to 60” 24. ETM-DRILL GUIDE KIT - 568418 Ø To guide, cool & lubricate hole saw Ø Designed for vertical & horizontal drilling Ø Diamond hole saws range from 1/16" to 4 1/2 " 25. SIGMA WATER DAM & GUIDE - 544607 Ø For drilling fast and accurate holes Ø Diamond hole saws range from 1/16” to 4 ½” 26. ETM-HOLE SAWS Ø Available in singles from 3/16” – 4 ½” Ø Available in 3, 5, 11 & 15 piece kits

27. ETM-SNAP - 566603 Ø Snaps tile after scoring

28. SIGMA SEPARATOR - 565852 Ø For splitting tile after scored

29. ETM-SPLITTER - 568411 Ø Splits very narrow pieces of tile up to 12mm thick (1/2”) Ø Designed to adjust to accommodate tile thicknesses between 5.6 & 12mm 30. EURO-NOTCH TROWEL - 538795 tile Ø Zipper trowel for maximum thin set coverage of 90-98% Ø Stainless Steel with soft grip handle Ø Trowel notch measures 1/2 X 3/8”

31. ETM-4 SIDED DIAMOND BLOCK - 566602 Ø To smooth the tile edge Ø 60, 200, 400, 600 grit sides 32. ETM-CORNER PROTECTORS Ø Set of 4 up to 8mm tile thickness

33. ETM-DOUBLE SUCTION CUP 568403 Ø For both smooth & rough tile 34. ETM-PUMP SUCTION CUP - 568406 surfaces Ø 8” Pump action suction cup Ø 200 LB capacity Ø Quick release lever Ø 150 LB capacity 35. ETM-WLFT FLOOR TOOL 565856 Ø Designed to apply proper tension with ease 36. ETM-WLS LIPPAGE FREE STRAP 566595 Ø Strap thickness reduced for clean and easy break 37. ETM-WLW LIPPAGE FREE WEDGE 565865 Ø Kick wedge from side for easy removal