This course will examine design and installation considerations for large format ceramic and porcelain tile (LFT). It will define the sizing categories for tile, and will address opportunities and constraints unique to LFT as defined by ANSI standards and TCNA methods. It will address bonding pattern recommendations, acceptable warpage and lippage, and acceptable minimums &variation in grout joint width. The program will also take a close look at substrate preparation for LFT including substrate flatness tolerances. Finally, the program will provide information on the newly defined category of thin Gauged Porcelain Tile (GPT) and thin GPT slabs/panels, including an update on the new ANSI standards currently for this product category.

1. DESIGN CONSIDERATIONS
FOR LARGE FORMAT TILE
INTERNATIONAL
MASONRY
INSTITUTE
Codes & Standards
Tile Categories
Grout Joint Width
Bonding Patterns
Gauged Porcelain Tile/Panels (GPT)
Lippage & Lighting
Substrates, General Req’ts
Substrate Flatness
Setting Materials & Coverage
Large Format Tile (LFT)
Movement Joints
Coefficient of Friction (COF)
Sustainability
Installer Qualifications
Installation Methods

2. Codes &
Standards
INTERNATIONAL
MASONRY
INSTITUTE

3. Codes & Standards

4. Large Format Tile
(LFT)
INTERNATIONAL
MASONRY
INSTITUTE

5. Large Format Tile
▪ Any side ≥ 15”

6. 12”x12”6”x8”8”x8”4”x8”6”x6”
ANSI A137.1
12”x24”24”x24”18”x36”24”x48”
18”x18”16”x16”
Tile Sizes

7. 3 ft.
Blue Cross Building, Philadelphia

8. Warpage
Lippage
Bonding pattern Substrate tolerance
Coverage
Grout joint
width
Large Format Tile, Issues

9. Gauged Porcelain Tile &
Gauged Porcelain Tile Panels
INTERNATIONAL
MASONRY
INSTITUTE

11. ANSI A137.3
American National
Standard Specification for
Gauged Porcelain Tile and
Gauged Porcelain Tile
Panels / Slabs
ANSI
A137.3
ANSI A108.19
Interior Installation of
Gauged Porcelain Tile
and Gauged Porcelain
Tile Panels by the Thin-
Bed Method bonded with
Modified Dry-Set Cement
Mortar
ANSI
A108
.19
New ANSI Standards

12. Standard porcelain tile
3 mm (1/8 in.) to
5.5 mm (7/32 in.)
GPT
ANSI
A137.3
ANSI
A137.1
Gauged Porcelain Tile (GPT)
7 mm (9/32 in.) to
14 mm (9/16 in.)

13. Back side of tile showing mesh reinforcement
Gauged Porcelain Tile (GPT)

14. Before After
Tile Over Tile

15. Tile Over Terrazzo

16. Crate is 124” long x 44” wide; 84” fork length required
Material Handling

17. Material Handling

18. Material Handling

19. Cutting & Drilling

20. Grout Joint Width
INTERNATIONAL
MASONRY
INSTITUTE

21. Grout Joint Width
Grout joint width is a function of:
▪ ANSI-established minimums
▪ Tile’s facial dimension tolerance
(range of tile sizes)
▪ Tile’s edge warpage

22. ▪ 12” x 12” porcelain tile, rectified
▪ What is the minimum grout joint width?
12” ?
Grout Joint Width

23. 4.3.8 Grout joint size: To accommodate the range in
facial dimensions of the tile supplied for a specific project,
the actual grout joint size may, of necessity, vary from the
grout joint size specified. The actual grout joint size shall
be at least three times the actual variation of facial
dimensions of the tile supplied. In no circumstance shall
the grout joint be less than 1/16 in.
ANSI A108.02.4.3.8
ANSI Minimum

24. ANSI A108.02.4.3.8
4.3.8 Grout joint size: To accommodate the range in
facial dimensions of the tile supplied for a specific project,
the actual grout joint size may, of necessity, vary from the
grout joint size specified. The actual grout joint size shall
be at least three times the actual variation of facial
dimensions of the tile supplied. In no circumstance shall
the grout joint be less than 1/16 in.
Facial Dimensions

25. 12” x 12” (nom.) Porcelain tile, rectified
▪ Dimension can vary ± .25% or .03 in.
▪ Allowable variation = 12 in. x .0025 = .03 in = approx. 1/32 in.
▪ 1/32 in. plus or minus = 1/16 in. allowable variation
Facial Dimensions
▪ Min. grout joint width = 3 x 1/16 in. = 3/16 in.

26. ANSI A108.02.4.3.8.1
“For running bond/brick joint patterns utilizing tiles
(square or rectangular) with any side greater than
15 in., the grout joint shall be, on average, a
minimum of 1/8 in. wide for rectified tiles and, on
average, a minimum of 3/16 in. wide for calibrated
(non-rectified) tiles. The grout joint width shall be
increased over the minimum requirement by the
amount of edge warpage on the longest edge of
the actual tiles being installed.”
LFT in Running Bond

27. 12” x 24” (nom.) Porcelain tile, rectified
▪ Grout joint width = 1/8 in. min., per ANSI A108.02.4.3.8.1
▪ Per table, longest edge warpage = 24 in. x .0040 = .096 in. = 3/32 in.
▪ Min. grout joint width = 1/8 in. + 1/16 in. = approx. 3/16 in.
▪ Conclusion: Don’t use large format tile in running bond!
▪ But per table, maximum is .05 in., or 1/16 in.
LFT in Running Bond

28. Bonding Patterns
INTERNATIONAL
MASONRY
INSTITUTE

29. No offset
50% offset
33% offset
Bonding Patterns, Large Format Tile

30. 50% offset (running bond)
Bonding Patterns, Large Format Tile

31. 50% offset (running bond)
Bonding Patterns

32. 50% offset (running bond)
Bonding Patterns

33. 50% offset (running bond)
Bonding Patterns

34. Bonding Patterns

36. Modular Tile

37. Modular Tile

38. Lippage & Lighting
INTERNATIONAL
MASONRY
INSTITUTE

39. Lippage
▪ Lippage: Condition where one edge of the tile is
higher than the adjacent tile, giving the surface
an uneven appearance.
▪ 1/32” – 1/16” lippage is acceptable, depending
on grout joint width.

40. ANSI A108.02.4.3.7
Lippage

41. Mechanical edge leveling system
Lippage

42. Lippage Control System
Lippage

43. Mechanical edge leveling system
Lippage

44. Overhead lighting next to the
wall creates harsh shadows,
emphasizes lippage
Lights moved just one ceiling
panel (24”) from wall
Locate light fixtures at least 24” away from the wall.
Lippage & Lighting

45. Wall wash lighting accentuates lippage, which may
be in the acceptable range
Lighting

46. ▪ It that’s impossible, insist that permanent lighting
type be placed in the permanent lighting location
prior to installing tile.
▪ Permanent lighting should be in place prior to tile
installation.
Construction Lighting

47. Installation Methods
INTERNATIONAL
MASONRY
INSTITUTE

48. ▪ Prep time reduced
▪ Thinner installation
▪ Limits deflection
▪ Can compensate for
irregular substrate
▪ Generally 1¼” to 2½” thick
Installation Methods
Mortar Bed (Mud Bed)
Thin-Set
3/32” - 1/4” after embedment
Medium bed mortar may be
3/16” – 3/4” after embedment

49. Mortar Bed Methods (Mud Work)

50. Thin Set Methods

51. “…Mortars are designed
as direct bond
adhesives and are not
intended to be used in
truing or leveling
underlying substrates or
the work of others.”
ANSI A118.4.2.1
ANSI
A118
Mortar for Large and
Heavy Tile (LHT)
“Medium Bed” is not a setting method

52. Substrate Flatness
INTERNATIONAL
MASONRY
INSTITUTE

53. Substrate Flatness
▪ Proper coverage
The flatter the substrate, the easier it will be
to achieve:
▪ Minimal lippage
Acceptable flatness Unacceptable flatness
▪ Better bond

54. “For tiles with all edges shorter than 15 in.,
the maximum allowable variation is no more
than 1/4 in. in 10 ft. and no more than 1/16
in. in 1 ft. from the required plane.”
“For tiles with at least one edge 15
in. or longer, the maximum allowable
variation is no more than 1/8 in. in 10
ft. and no more than 1/16 in. in 2 ft.
from the required plane.”
Standard size tile
Large format tile (LFT)
ANSI A108.02.4.1.4.3.4
Requirements for sub-floor surfaces and vertical surfaces to receive
tile using one of the thin-set methods:
Substrate Flatness

55. For tiles with all edges shorter than 15 in., the maximum allowable
variation is no more than 1/4 in. in 10 ft.
ANSI
A108
Substrate Flatness
For tiles with at least one edge 15 in. or longer, the maximum
allowable variation is no more than 1/8 in. in 10 ft.

56. ANSI
A108
Substrate Flatness
Required plane
For tiles with at least one edge 15 in. or longer, the maximum allowable
variation is no more than 1/16 in. in 1 ft. from the required plane.
For tiles with at least one edge 15 in. or longer, the maximum allowable
variation is no more than 1/16 in. in 2 ft. from the required plane.
Required plane

57. Substrate Flatness

58. Substrate Flatness

59. Self-leveling underlayment
(SLU)
Trowel applied patch
(flash patch)
Substrate Flatness

60. Division 3 (FF method)
vs. Division 9 (10 ft.
straightedge method)
Substrate Flatness

61. Division 3, Concrete
▪ Concrete floors must comply with a floor flatness (FF)
tolerance based on the ASTM E1155 Standard Test
Method to Determine Floor Flatness and Floor
Levelness Numbers
- FF of 20 is conventional
- FF of 35 is flat
- FF of 60 is superflat
- per ACI 117-06, is suitable for
thin-bed tile installations
- however, FF of 35 will often have areas that
do not meet the required flatness for tile
Substrate Flatness

62. Limitations of ASTM E1155 (FF method)
▪ Measurement taken within 72 hours of concrete placement
- Before concrete curling and shrinkage
▪ No measurement taken at
construction, isolation, or
control joints.
▪ No measurement taken at
column blockouts.
▪ No measurement taken
within 2 feet of perimeter
of slab.
Substrate Flatness

63. CONCRETE IS FLAT
WHEN CAST IN PLACE
CONCRETE IS FLAT
WHEN CAST IN PLACE
BUT CURLS AND
SHRINKS AS IT SETS
▪ Most curling is caused by shrinkage
as the concrete dries
▪ As the slab top shrinks, the bottom
doesn’t, and the slab curls
▪ Possible remedy: place more
reinforcement at the top of the slab
Substrate Flatness

64. Straightedge Method
Tile contractor checks individual areas with a 10-ft
straightedge
▪ 1/4 in. in 10 ft. for standard tile
▪ 1/8 in. in 10 ft. for LFT
▪ Often, floors that meet FF of 35 will have
areas that do not meet these criteria.
Substrate Flatness

65. Unless subfloor prep is required by the spec, or a
bid allowance is included, tile contractor assumes
a suitably flat floor will be provided.
TCNA Handbook
“Project specifications shall include a specific and
separate requirement to bring the subsurface into
compliance if a thin-bed method is specified but
subfloor does not meet the flatness requirements.”
Substrate Flatness

66. “As tile size increases, the
effect of substrate
irregularities is compounded.
When specifying tile with any
edge longer than 15”,
consider specifying a
recessed substrate and a
mortar bed (thick-set)
installation method to
minimize lippage that results
when a thin-bed method is
specified but subfloor flatness
requirements are not met.”
TCNA Handbook
Substrate Flatness

67. “…Mortars are designed
as direct bond
adhesives and are not
intended to be used in
truing or leveling
underlying substrates or
the work of others.”
ANSI A118.4.2.1
Substrate Flatness

68. Installer
Qualifications
INTERNATIONAL
MASONRY
INSTITUTE

69. Training

70. TCNA Handbook Language

71. “Journeyman Tile Layers Apprenticeship
Programs… Contractors that employ union
Journeymen Tile Setters can be found
through the Union Locals that list their
signatory contractors, primarily the
Bricklayer and Allied Craftworkers (BAC)…
“Every aspect of a tile installation relies on
the tile contracting company and its
installers.”
“The following non-profit programs are
well-established and recognized by the
Handbook Committee:
“Tile Contractors’ Association of America
(TCAA) Trowel of Excellence Program…”
“IMI Contractor College…
TCNA Handbook Language

72. TCNA
TCNA Handbook

73. New in 2015:
TCNA
TCNA Handbook

74. 09 30 00 Tiling

75. Hard Rock Casino, Northfield, OH
Project Specification Example

76. Manufacturer Literature Example

77. Qualified Labor in Specifications

78. Qualified Labor in Specifications

80. ACT-certified Installer
Pass hands-on
skills assessment
3.
Pass written exam
based on TCNA &
ANSI Standards
2.
BAC Journeyman
or certified by CTEF
1. ❖ IMI pre-apprenticeship
❖ 3-4 year BAC apprenticeship
❖ or CTI certification
❖ Orientation class
❖ Study materials provided
❖ Open-book test
❖ Minimum passing grade 84%
❖ Tests are widely available
❖ Judged by certified evaluator
❖ Judged on critical points
❖ Testing and criteria are consistent
❖ Certified in one or more skills
❖ Certification good for 3 years
❖ Credential is held by the installer
STEPS TO BECOMING AN ACT-CERTIFIED INSTALLER

81. Certifications

82. Certifications

83. Certifications

84. Certifications

85. Certifications

86. Certifications

87. Certifications

88. TCNA
Certifications

89. www.tilecertifications.com

90. Expiration Date
01/01/2016
Certifications

91. Specification Language

92. ANSI A108.19
Installing Contractor
10.1 Due to the unique material characteristics and
unconventional installation techniques required of gauged
porcelain tiles and gauged porcelain tile panels/slabs, this work
requires installers who are equipped with the proper tools and
have acquired sufficient product knowledge and installation
experience through the completion of an Installer Qualification
Program as listed in 10.2.
10.2 Installer Qualification Programs
10.2.1 Installer certified by Advanced Certification for Tile
Installers (ACT) program for Gauged Porcelain Tiles and
Gauged Porcelain Tile Panels/Slabs.
www.tilecertifications.com

93. INTERNATIONAL
MASONRY
INSTITUTE
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This concludes The American Institute of Architects
Continuing Education Systems Course
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DESIGN CONSIDERATIONS
FOR LARGE FORMAT TILE