Porcelain Finish Panel Owner s Manual

Porcelain Finish Panel Owner s Manual

Table of Contents Porcelain Care and Maintenance... 2 Cleaning Procedures... 2 Owner s Tool List... 3 Panel Removal and Replacement... 3 General Guidelines and Safeguards... 3 Removing Panels... 4 Replacing Panels... 4 Stringer Removal and Replacement... 4 Stringer Removal and Replacement Guidelines... 4 Floor Panel Load Capacities... 5 Protecting the Floor from Rolling Loads... 5 Verifying Equipment Loads are within the Capacity of the Floor... 5 Single Piece Porcelain Panels... 5 Service Load Capacity: 1,000 lbs.... 5 Move-in Rolling Load Capacity: 800 lbs.... 5 Daily or Frequent Rolling Load Capacity: 600 lbs.... 5 Multi-Piece Porcelain Panels... 6 Service Load Capacity: 600 lbs... 6 Move-in Rolling Load Capacity: 400 lbs.... 6 Daily or Frequent Rolling Load Capacity: 400 lbs.... 6 Protecting the Floor... 6 Protecting the Floor from Wheel Marks during Move-in... 6 Protecting the Floor from Day-to-Day Use... 6 General Rolling Load Safeguards... 6 Cutting Panels... 7 Cutting Safety... 7 Cutting Tools and Equipment... 7 Cutting Methods for Panels... 8 Best Practices for Panel Cutting... 8 Page 1

Porcelain Care and Maintenance Tate s porcelain panels are designed for years of service with minimum maintenance. Adherence to the guidelines below allows maximum life to be obtained from this tile. The panels should not be exposed to construction traffic and must be protected just as any finished floor coverings. Do: 1. Provide protection from sand and chemicals tracked in on shoes by providing "walk- off mats" at entrances. 2. Rotate panels in high-use areas to areas of low traffic to spread years of wear over the entire system. 3. Use felt furniture glides designed for hard surface finishes. Metal or plastic glides designed for carpet should not be used on porcelain flooring. 4. Use chair mats under casters. Casters should be soft rubber and designed for hard surface finishes 5. Keep the floor clean by light damp-mopping with a mild multi-purpose floor cleaner or mild detergent. Don't: 1. Flood the floor or use anything other than a damp mop. 2. Use strong abrasives, steel wool, nylon pads or scrapers to remove stains. 3. Use wax and/or similar products 4. Use cleaners which contain hydrofluoric acid, a very aggressive agent that should never be used. Cleaners containing hydrofluoric acid attack ceramic materials even if strongly diluted. 5. Drag or slide furniture or equipment across the floor without the use of glides. Cleaning Procedures Initial care can be carried out with a damp microfiber mop or a buffing machine. For either option, the first step is to sweep and vacuum any loose dust, dirt or debris from the floor. It is important not use excessive water or flood the floor. Water may not pool on the floor or seep between the seams of the panels. Microfiber floor mop Use a slightly damp mop with a high proportion of microfibers (at least 50%). For lightly textured floor tiles, use a deep-pile microfiber mop. If desired, add a small amount of mild detergent or vinegar to the water. Make sure that the cleaning product is suitable for unglazed floor tiles. http://www.uline.com/bl_8823/microfiber-wet-mops Microfiber Mop Page 2

Buffing machines or auto scrubbers For more tenacious dirt, spray a fine mist of cleaning solution on the floor and polish with a red or blue pad or dry buff with a white scrubbing pad suitable for use on unglazed floor tiles. Make sure that the cleaning product is suitable for unglazed floor tiles. Minimal water should be used. Auto scrubbers may only be used if the water does not seep between the seams of the panels and does not pool on the floor. Once cleaning is completed, isolate the cleaned floor until it has completely dried. http://www.cleanfreak.com/equipment/floor/buffers/17-inch-rotary-floor-buffer.html Scrubber drier machines Regular vacuuming or wiping prevents the accumulation of dust and dirt. The floor will need to be cleaned regularly to remove more tenacious dirt. Prior to cleaning, first remove loose dirt by vacuuming or sweeping. Use a slightly damp mop with a high proportion of microfibers (at least 50%). For lightly textured floor tiles, use a deep-pile microfiber mop. If desired, add a small amount of mild detergent or vinegar to the water. Make sure that the cleaning product is suitable for unglazed floor tiles. Auto Scrubber http://www.clarkeus.com/products/autoscrubbers/vantage14.aspx Owner s Tool List Scrubber Drier Machine 1. Tate s double suction cup lifter, Price List part number 595922. 2. Battery powered torque limiting screw gun, DeWalt, Hitachi, or Mikita 3. Replacement tips for the screw gun, #3 Phillips 4. #3 Phillips screw driver Panel Removal and Replacement General Guidelines and Safeguards 1. To keep the floor straight and square, it is best to remove panels only where immediate access is required and reinstall panels as your work progresses. When removing several panels at a time, no more than six adjacent panels should be removed at once. 2. Do not drag or slide the panel across the floor when putting a panel to the side. Dragging a panel can cause separation of the edge bands from the sides of the panel. 3. Do not attempt to carry a panel by the lifter the suction could break and allow the panel to fall from your hand. 4. When removing and reinstalling cut panels at the floor perimeter and around columns, reinstall each cut panel from where it was removed. Perimeter panels are precisely cut for each location. Interchanging perimeter panels that may have been cut to different sizes can cause floors to become out-of-square or cause sections of the floor to become tight or loose. Page 3

Removing Panels 1. To remove the first panel from the floor, kneel in front of the panel you want to remove. 2. Attach the double suction cup lifter near the edge of the panel and lift the end facing you a couple of inches. 3. With the opposite end of the panel resting on the stringers, tilt the panel up by hand (not using the lifter) and stand up. 4. Grasp both sides of the panel and lift the panel from the floor. Lay the panel to the side without dragging it across the floor. 5. Once the first panel is out of the floor, nearby panels can be removed either by using the lifter or by reaching under the panels and pushing upward. Replacing Panels 1. When more than one panel in a row is removed from the floor, it is possible to replace all but the last panel without using the suction cup lifter provided there is sufficient working room under the floor to position the panels into place. The lifter can also be used to position the panels into place. 2. The last panel must be positioned on the stringers using the lifter. Attach the lifter near the center of the panel. Lower the panel into the opening by hand and use the lifter to slightly lift and move the panel into place. 3. Be careful not to slide panels across the floor when reinstalling them as doing so can scratch the floor surface. Stringer Removal and Replacement Stringer Removal and Replacement Guidelines 1. When it is necessary to remove stringers, it is best to remove only a couple of stringers at a time where immediate access is required and reinstall them as your work progresses to keep the floor straight and square. 2. Use a torque limiting screw gun with #3 Phillips bit set to 30-inch pounds. 3. Do no over-tighten the screws because doing so can cause the stringers to spread out at bottom. 4. Do not under-torque the screws because doing so can cause the system to become loose. Have a Question? Call Tate s Technical Hotline 1-800-231-7788 or visit our website at www.tateinc.com Page 4

Floor Panel Load Capacities Special note for floors with single piece and multi-piece porcelain panels: A panel laminated with multiple pieces of porcelain tile has lower load ratings than a panel laminated with a single piece of tile. Be careful not to exceed the load limits on multipiece tile panels if both styles exist in a floor. Protecting the Floor from Rolling Loads Verifying Equipment Loads are within the Capacity of the Floor Rolling equipment and vehicles such as, dollies, pallet jacks, and lifts that exceed the floor s capacity can damage the floor. Check the equipment manufacturer s specifications to verify that your payload combined with the load of the equipment you want to use will not exceed the rolling load capacities indicated below. Single Piece Porcelain Panels Service Load Capacity: 1,000 lbs. A panel will support a load of up to 1,000 lbs. load concentrated on a single leg or foot or on any larger area. Alternatively, a panel will support multiple concentrated loads simultaneously provided the total load does not exceed 1,000 lbs. Move-in Rolling Load Capacity: 800 lbs. For equipment and furniture move-ins, loads of up to 800 lbs. can be rolled across each panel at one time. The load can be imposed through a single wheel or two wheels simultaneously provided the total load does not exceed 800 lbs. Daily or Frequent Rolling Load Capacity: 600 lbs. For routine rolling load traffic, loads of up to 600 lbs. can be rolled across each panel at one time. The load can be imposed through a single wheel or two wheels simultaneously provided the total load does not exceed 600 lbs. Page 5

Multi-Piece Porcelain Panels Service Load Capacity: 600 lbs. A panel will support a load of up to 600 lbs. load concentrated on a single leg or foot or on any larger area. Alternatively, a panel will support multiple concentrated loads simultaneously provided the total load does not exceed 600 lbs. Move-in Rolling Load Capacity: 400 lbs. For equipment and furniture move-ins, loads of up to 400 lbs. can be rolled across each panel at one time. The load can be imposed through a single wheel or two wheels simultaneously provided the total load does not exceed 400 lbs. Daily or Frequent Rolling Load Capacity: 400 lbs. For routine rolling load traffic, loads of up to 400 lbs. can be rolled across each panel at one time. The load can be imposed through a single wheel or two wheels simultaneously provided the total load does not exceed 400 lbs. Protecting the Floor Protecting the Floor from Wheel Marks during Move-in To prevent wheel marks or scuffs from forming on the floor during move-in, use non-marking tread wheels, or cover the floor in the load path with Masonite or plywood. To Use Masonite or plywood: 1. Tape plastic sheets to one another and to the floor surface. 2. Lay 3 16 or ¼ thick sheets of Masonite or ½ thick sheets of plywood on top of the plastic and tape together with duct tape. Protecting the Floor from Day-to-Day Use To prevent scuffs, scratches, and uneven wear, use felt furniture glides and soft rubber nonscuff casters designed to be used on hard surface finishes. Metal or hard plastic glides, feet and casters for carpet should not be used on porcelain flooring. Avoid dragging furniture or heavy objects across the floor without protecting the finish. Use of walk-off mats at entrances and rotating panels from heavy traffic areas will help extend the life of the panel s finish. Follow the care and maintenance instructions for proper cleaning and daily up-keep. General Rolling Load Safeguards 1. Make sure all floor panels in and around the load path are in place to prevent the floor from shifting. 2. Do not allow heavily loaded vehicles to drop to the floor when stepping down from a higher level. Page 6

Cutting Panels Cutting Safety All governing organizational safety standards must be followed and practiced at all times. Proper Personal protection equipment should be worn during the cutting process. Tate recommends the following personal protection equipment be utilized; however, this is not an allencompassing list for every situation. Personal Protection Equipment Safety glasses Ear plugs / muffs Steel toe safety boots with aggressive slip resistant tread NIOSH approved face mask Snug, flexible safety gloves Equipment Needs All cutting equipment guards and shields be in place Ground Fault Interrupter System Cutting Tools and Equipment Panels with porcelain tile can be cut in either of the following ways: 1. Cut through the tile down to the surface of the ConCore panel using a circular saw or grinder then cut through the panel using a band saw with bi-metal blade. 2. Simultaneously cut through the tile and the ConCore panel using a band saw with carbide grit blade. Cutting through the tile and panel with a band saw with carbide grit blade will be a slower operation however it may be necessary to do when making curved cuts or when cutting inside corners in panels. Recommended Circular Saws, Grinder and Blades for Cutting through Porcelain Tile: Table saw for straight cuts through porcelain tile: IMER Combi 250VA 10 inch Tile & Stone Saw http://www.imerusa.com/saws_tpss.htm a. Pearl Wet Porcelain Blade http://pearlabrasive.com/pages/itemclass_catalog.aspx?search_val=porcelain& search_type=product&-class=&advanced=0 Hand held circular saw for curved or straight cuts through porcelain tile: Makita 12V max CXT Lithium-Ion Cordless Tile/Glass Saw Kit (CC02R1) with 3-3/8 blade https://www.makitatools.com/products/details/cc02r1 a. Makita 3-3 / 8 Wet/Dry Diamond Blade https://www.makitatools.com/products/details/724950-8d Angle grinder for curved cuts through porcelain tile: Hilti AG 450-7D angle grinder with 4.5 disc. (The grinder is also useful for making inside corner cuts in the tile and panel.) Page 7

https://www.hilti.com/cutting,-sawing-&-grinding/cutting-&-grinding/anglegrinder/r2328133 a. F Series Granite Turbo Blade / DTB-F- by A.Bottini Enterprises Inc. https://abottini.com/collections/diamond-blades/products/f-series-granite-turboblades Recommended Saws and Blades for Cutting Panels and Understructure: Mobile Applications Model MA-615 Band Saw Wilton Model 8201 Band Saw DeWalt 331K Hand-held Jig Saw Blade: Lennox Classic HSCO Bi-Metal M42 band saw M42 ¾ x.035 14 WS (This blade will not cut porcelain.) Recommended Band Saw Blades for Cutting through both Panel and Tile: Lenox Master-Grit Carbide band saw blade ¾ x.032 Gulleted - Course Lenox Master-Grit Carbide band saw blade ½ x.025 Continuous Medium http://www.lenoxtools.com/pages/master-grit-carbide-band-saw-blades.aspx Cutting Methods for Panels Factory-supplied Cutouts Tate provides factory cutouts precisely made by water jet cutting and can provide panels with any size and shape of interior cut. Water jet cutting is the easiest and most efficient method of simultaneously cutting through the floor panel and the porcelain. Best Practices for Panel Cutting 1. Locate the panel cutting operation in a place that will prevent or minimize dust generation in installation areas. 2. Cut panels should be cleaned with wet rags before installing them in the floor. Tips for Cutting Perimeter Panels 1. Perimeter panels should be measured and cut to fit at each location taking into consideration that walls may be wavy or out of square. Measurements should be made twice to ensure that panels are cut tight to the wall or curb. When making complex cuts we recommend the use of cardboard panel templates before cutting actual panels. 2. The edges of perimeter panels cut to walls, columns and curbs can be beveled from the top to make panel removal and installation easier. A 5 degree bevel cut is adequate. Making Straight Cuts with a Circular Saw 1. Make straight cuts through the porcelain tile using a bridge saw such as the Combicut 250VA wet cutting tile & stone saw or a hand-held circular saw such as the Makita 12V CXT saw. 2. After cutting through the porcelain tile, cut through the ConCore panel is using a metal cutting band saw with a Bi-Metal blade. Page 8

Making Curved Cuts with a Hand-held Circular Saw or Grinder 1. To make slightly curved cuts through the porcelain tile use the Makita 12V CXT saw or the Hilti AG 450-7D angle grinder with 4.5 disc. 2. To make tight curves in panels use the Hilti angle grinder. 3. After cutting through the porcelain tile, cut through the ConCore panel is using a metal cutting band saw with a Bi-Metal 14 TPI ½ x.035 blade (or similar blade). Creating and Inside Corner Cut in a Panel (Cutting a Panel into an L Shape) 1. You can use a carbide grit blade on your band saw to simultaneously cut through the tile and the panel. Note that this method of cutting is slower than using a circular saw. 2. If using a circular saw to cut through the porcelain tile you need to stop the cut before the blade cuts through the full depth of the tile then use a carbide grit blade on your band saw to complete the cut through the tile and the panel. Minimizing Saw Blade Wear 1. Try to minimize cutting into the ConCore panels with your tile cutting saw to minimize dulling of your tile cutting blade. 2. Try to minimize cutting through the porcelain tile with your band saw to minimize dulling of your band saw blade. Page 9

Corporate Headquarters: 7510 Montevideo Road, Jessup, MD 20794 Tate Hotline: 1-800-231-7788 Tel: +1 410 799 4200 Fax: +1 410 799 4207 Production Facilities: 7510 Montevideo Road, Jessup, MD 20794 52 Springvale Road, Red Lion, PA 17356 Tel: +1 717 244 4071 Fax: +1 717 246 3437 Canadian Sales & Support Office: 880 Equestrian Court, Oakville, ON L6L 6L7 Canada Tate Hotline: 1-800-231-7788 Tel: +1 905 847 0138 Fax: +1 905 847 0141 Asia Sales & Support Office: 19 Cecil Street #05-15, 5th Floor, The Quadrant Singapore 049704 Tel: +65 6653 5358 Central and South American Sales & Support: Tel: +1 443 995 1808 European Sales & Support: B16 Ballymount Corporate Park, Ballymount Avenue, Ballymount, Dublin 12, Ireland Tel: +353 (0) 87 1238383 Middle East Sales & Support: Jebel Ali-Lahbab Road (E 77 Road) Dubai Investment Park United Arab Emirates Tel: +971 56 199 8368 Australian Sales & Support Office: 28 Biloela Street, Villawood NSW 2163 Tel: +61 02 9728 4111 Fax: +61 02 9728 3088 Page 10