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DuraCeramic is an innovative flooring product with unique installation procedures that vary from traditional ceramic and natural stone. Its proven success has paved the way for DuraCeramic Options, a floor and wall tile with embossed lines through the center of the tile in both directions. The tiles can be installed like DuraCeramic, in a full 16" x 16" format or the embossed lines can be scored with a sharp utility knife and flexed to separate the tile to create an 8" x 8" format. This feature provides opportunities for creating custom floors with coordinating wall, base and backsplash by adding accent colors, borders and insets or combining it with DuraCeramic for different size formats. DuraCeramic and DuraCeramic Options are constructed with a limestone composite base that is fortified with a polymeric resin. That provides toughness and flexibility to resist breaking from normal subfloor deflection, expansion and contraction. This feature permits fast, easy installation using a pressure-sensitive adhesive and a flexible grout over a wide variety of wall and subfloor surfaces without extensive preparation.

-DS100 DuraSet Adhesive – For all approved floor and wall applications

- DuraCeramic Premixed Grout – For joints on grouted floors and walls

- DS200 DuraCeramic Joint Sealer - For joints on ungrouted floors only

- DuraCeramic Installation Accessory Kit- For grouted applications

DuraCeramic and DuraCeramic Options are recommended for residential and light commercial use in dry, interior, heated areas.

Recommended for use in all areas of the home except countertops,ceilings and wet areas like shower walls and shower floors.

Recommended for areas receiving light commercial foot and wheel traffic. Install on floors, walls, and facing of counters and merchandise displays.

• Specialty Shops

• Beauty Salons

• Clothing and Apparel Shops

• Boutiques

• Doctors’ Offices Waiting Room

• Dental Offices Waiting Room

• Retirement Facilities - Suitable for Light Wheel Chair Traffic

Notes:

DuraCeramic and DuraCeramic Options are not recommended for installation in exterior or unheated areas, wet areas, like shower walls or shower floors, countertops, ceilings, in commercial kitchens or food processing areas or on ramps. For information on other specific applications, contact the Congoleum Installation and Technical Office at (609) 584-3888. Areas receiving more concentrated traffic and or routine spills should be protected with floor polish and a regular maintenance schedule should be followed. See Care and Maintenance for more information.

16" x 16" DuraCeramic Options with embossed lines Score and separate into 8" tiles for an 8" x 8" grouted installation.

• Lobby

• Reception Area

• Conference Room

• Lounge

• Offices

• Restrooms

• Dining Areas

• Hospitality Rooms

• Lounges

• Guest Rooms

• Administrative Lounges

• Dormitory Rooms

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Order Code DS100 DS200 Use specific color code

Description Solvent free, acrylic, pressure- Water-based, flexible Premixed sanded, acrylic grout sensitive adhesive acrylic sealerUse Installing tile over all For sealing joints in ungrouted For use with DuraCeramic approved substrates and DuraCeramic floors only. in grouting joints 1/16" to 1/4" wall surfaces Not recommended for walls wide. Can also be used for or vertical surface. grouting most ceramic and porcelain floor tile.Limitations Not recommended for ceramic, Not recommended for ceramic, Not recommended for porcelain, or natural stone. porcelain, or natural stone. nonvitreous tiles or natural stone, exterior use, shower floors or underwater use.

Coverage 200 to 250 sq. ft. per gallon 320 sq. ft. per 8 oz. bottle Joint Width Approximate Coverage

16" x 16" Tile

1/16" (1.6mm) 450 sq. ft./gal. (42m2)

1/8" (3.2mm) 325 sq. ft./gal. (31m2)

3/16" (4.8mm) 275 sq. ft./gal. (26m2)

1/4" (6.4mm) 225 sq. ft./gal. (21m2)

8" x 8" Tile

1/16" (1.6mm) 225 sq. ft./gal. (21m2)

1/8" (3.2mm) 165 sq. ft./gal. (16m2)

3/16" (4.8mm) 140 sq. ft./gal. (13m2)

1/4" (6.4mm) 115 sq. ft./gal. (11m2)

Applicator 1/16" wide, 1/32" deep, Applicator nozzle included Hard rubber float or green

1/32" apart , trowel blade epoxy float. Cleanup with firm adapter included sponge and 3M pad.

Working Time Floors: 12 hours. Dry to tack - 45 N/A 10 minutes- for best results apply to 60 min. under normal conditions. grout in a 20 sq. ft. area on floors or a Walls: 10 to 20 minutes. Dry to 10 sq. ft. area on walls and clean up tack - 20 to 30 minutes. immediately.Set Up Time N/A Tack free -1 hour; 16 to 24 hours

Set up - 8 hours

Clean Up Wet - Water Wet - Water Wet - Water Dry - Mineral spirits Dry - Mineral spirits Dry - Household ammonia cleaner.Do not use grout haze removers.

Color Pale blue, turns clear when White, turns clear when dry Popular versatile colors tacky dry available

Tracers Dark Red N/A N/A

Unit Size 1 quart; 1 gallon; 4 gallons 8 oz. bottle 1 gallon

Shelf Life 1 year if unopened 1 year if unopened 1 year if unopened

Freeze/Thaw Stability Yes Yes Yes

Flammable No No No

Cautions Potential skin and eye irritant Potential skin and eye irritant Potential skin, eye and respiratory irritant

DS100 and DS200 - WARNING: Potential eye and skin irritant.

DuraCeramic Premixed Grout - WARNING: Potential eye, skin and respiratory irritant.

Mineral spirits - Caution: Flammable material; read and follow cautionary statements on label.

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-Always store and transport cartons on a flat surface stacked no more than 10 cartons high. Handle tiles and cartons with care. Tiles can be damaged if dropped.

-Condition the room(s) and all flooring and setting materials at a constant temperature between 65°F (18°C) and 85°F (29°C) for 48 hours prior to, during, and 48 hours after installation. Thereafter, maintain a room temperature between 55°F (13°C) and 100°F (38°C).

-Do not install at a temperature higher than 85°F (29°C).¡ When installing tile from two or more cartons, check the code on the side of the cartons to ensure that the pattern and shade numbers are the same. Mix tiles from several different cartons to achieve the best appearance.

-For the best visual results, the directional arrows printed on the back of the tile should be installed following Fig. 1,with tiles turned randomly, i.e. north, south, east and west.

DuraCeramic Options is designed with embossed center lines. To create an 8"x 8" format, score the embossed line(s) with a sharp utility knife and flex the tile to separate the sections. If necessary, use a sanding block with 100 grit open face sand paper to remove roughness at the separation edges.

Once DuraCeramic Options is separated, it must be grouted.

(Fig. 2 and Fig. 3).

• Notched trowel (1/16" wide, 1/32" deep, 1/32" apart)

• 100-pound, three-section, steel roller

• Grout tools and spacers for grouted applications

• 18" tile cutter - optional

DuraCeramic may be installed over dry concrete on all grade levels, suspended wood, qualifying old resilient floors, ceramic tile and terrazzo.

Fig. 1 - Turn tiles as shown.

Fig. 2 - Score with a sharp utility knife.

Fig. 3 - Flex tile and separate into 8" tiles.

Size (nominal) 15 5/8" x 15 5/8" (40 cm x 40 cm)

Gauge (nominal) .160" (4.1 mm)

Packaging 10 Pieces/Carton

17 Sq. Ft.; 1.58 m2

Shipping Weight 33 Lbs./Carton

NBS Smoke Density Passes

Critical Radiant Flux

(ASTM E648 >0.45w/cm2) Passes

Motor Vehicle FMVSS 302 Passes

Static Load Limit 250 psi

Slip Resistance Meets ADA Recommendations

PEI Rating 3-4

Installation Method Grouted or Traditional Edge-to-Edge Fit (Ungrouted)

Subfloor Application On, Above, or Below- Grade Level

Adhesive Congoleum DS100 DuraSet Adhesive

Grout DuraCeramic Premixed Grout

Joint Sealer

(Recommended for DS200 DuraCeramic ungrouted floors) Joint Sealer Suggested Usage Residential and Light Commercial Residential - Lifelong

Warranty Lt. Commercial - Five-Year Commercial

The surface must be clean, dry and free of dust, dirt, grease or other extraneous material that will inhibit bonding. Thoroughly vacuum floor to remove dust.

-Deviations in the flatness of the subfloor cannot exceed1/16" in 1’ or 3/16" in 10’.

Check the surface with a straightedge and fill low areas with a portland cementbased latex patching compound. Gypsum-based patching compounds are not recommended.

-The use of a high-quality latex primer that is specifically designed to improve adhesion may be used over wood,porous concrete and patching compounds prior to adhesive application. The primer will help seal the surface and tie down dust that can interfere with the adhesive bond. Do not use paint primers.

Concrete must be clean, dry, and free of paint, curing, hardening and parting compounds, sealers, and old adhesive residue. Moisture vapor emissions should not exceed 5 lbs./1000 ft.2/ 24 hrs when tested with the calcium chloride kit. Do not install DuraCeramic or DuraCeramic Options over expansion joints; instead, cut the tile neatly to each side of the joint and fill it with an elastomeric polyurethane joint filler or cover with an expansion plate cover.

Wood subfloors must be structurally sound and free of movement with at least 18" of well-ventilated air space below. Single layer floors and stripwood floors must be covered with a 1/4" or heavier underlayment to achieve a total subfloor thickness of 1". Position underlayment joints so they offset the joints in the tile by at least 3". Sand underlayment joints level and fill gaps wider than 1/32" with the recommended patching compound.

-Layout is slightly different for grouted and ungrouted floors. The grout line width must be added to the tile dimension for layout on grouted floors. Additional chalk lines are also used to keep the joints straight. Nominal tile size is 15 5/8" x 15 5/8". DuraCeramic Options is 7 13/16" x 7 13/16" when scored and separated.¡ It is important to avoid positioning the tile joints directly over underlayment joints or seams in existing flooring. If this should occur, reposition chalk lines to offset joints by at least 3" or half of the tile dimension.

• Place a mark in the center of the floor at each end of the room. Then snap a chalk line between the marks.

• Find the center of the line and snap a second chalk line at a right angle; use the 3’, 4’, 5’ method to form a right angle (Fig. 4).

• Make a dry layout in one quadrant along the center and perpendicular chalk lines. Remember to allow the desired

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Subfloor

Construction/ Comments Notes

Materials

Wood • Double layer construction over Subfloor must joist or trusses on 16" centers with be solid and at least 18" of well-ventilated free of air space. movement.

• Install 1/4" or heavier underlayment over strip wood, single layer wood floors and APA-rated Sturd-I-Floor Systems.

Underlayment • APA underlayment grade Install accordplywood with fully sanded face. ing to panel

• Hardwood and veneer under- manufacturers’ layment panels such as Multiply, written instruc- HU 845 Tec-Ply and Ulay. instructions.

• Lauan plywood, particleboard, oriented strand board and chipboard create a higher risk for installation and adhesive failure and are not recommended unless warranted by the panel manufacturer or supplier.

• Not recommended over cement backer-boards, glass mesh mortar units or acoustical cork.

Concrete • On, above and below-grade level. Moisture vapor

• Radiant-heated floors not to emissions not exceed 85°F (29°C). to exceed 5 lbs.

Light Weight

• Minimum 100-pound density Confirm Concrete

• Installation over gypsum-based adequate (Residential acoustical toppings is not adhesion to Application only) recommended. substrate. Resilient Floor

• Smooth, non-cushioned sheet Must be single (SeeWARNING flooring and vinyl composition tile. layer, fully on inside cover)

• Embossed non-cushioned and thin adhered and cushioned vinyl flooring can be well bonded. prepared with embossing leveler in Remove wax residential applications. or polish.

• Do not install over soft, heavy cushioned floors, self-adhering tile or tile installed below grade level. Ceramic and Ceramic, marble and granite. Fill grout joints Stone level.

Carpet

• Not recommended. Remove Laminate Patching

• Portland cement-based compound Refer to Compound such as Ardex Feather Finish, manufacturers’ Mapei Plani-Patch or equal. instructions or Gypsum-based patching use and compounds are not recommended. applications.

Fig. 4 - Square layout.

grout line space between the tiles. A story pole (board marked with tile dimensions, including grout line width) can also be used in place of a dry layout.

• Measure the distance between the last whole tile and the wall. If the distance is less than half a tile, snap a new chalk line one-half the dimension of a full tile away from the original chalk line (Fig. 5). This will provide a balanced layout with larger cut tile at the border.

• When installing grouted floors, divide the floor into smaller sections to help maintain consistent grout line widths and keep the joints running straight (Fig. 6). Each section should be the precise dimension of 2 or 3 whole tiles wide, including the grout line width. Lay out the smaller sections by starting at the center lines and measuring out toward the walls. It is not necessary to divide the room into smaller sections when installing ungrouted floors.

Note: Chalk lines can be easily removed or difficult to see after applying adhesive over some subfloor surfaces like old flooring and concrete. To avoid loosing the lines, mark the subfloor with a pencil and a straightedge, directly over the chalk lines

Congoleum DS100 DuraSet Adhesive is a pressure-sensitive adhesive that must be allowed to dry completely to a tack before setting tiles. (See Special Instructions for Wall Applications). Apply the adhesive with the trowel blade ttachment included with the adhesive. The recommended trowel notch size, 1/16" wide, 1/32" deep, 1/32" apart.

-Spread the adhesive over one-half of the subfloor and a few inches beyond the center chalk line.

-Allow the adhesive to dry completely to a tack before installing the tile. Normal dry to tack time is about 45 to 60 minutes; longer in cool or humid conditions. The adhesive will turn from light blue to clear when tacky dry and will not transfer to the finger when firmly touched. Donot use fans to accelerate adhesive drying time. Fan drying can cause the top surface of the adhesive to dry prematurely, trapping residual moisture in and preventing the adhesive from fully curing.

-Tile must be installed within 12 hours after adhesive turns clear.

Carefully position the first tile into the adhesive at the intersection of the chalk lines (Fig. 7). The tile will bond instantly on contact so it must be positioned accurately without sliding it. Press the tile firmly into the adhesive. Follow the procedures below for grouted and ungrouted floors.

• The desired grout line width should be determined prior to starting the flooring installation. It is important to understand that the finished grout line will be 1/16" to 3/32" wider than the space between the tiles, since the grout will extend up, onto the radius, along the top edge of the tile (Fig. 8).

Fig. 6 - Lay out smaller sections for grouted floors.

Fig. 5 - Adjust layout at center lines for larger border tiles.

Fig. 7 - Positioning tiles.

Fig. 8 - The finished grout line width is wider than the space between the tiles.

GROUT

• If standard tile spacers are used, it will be necessary to remove one leg of the spacer (Fig. 9) otherwise it will interfere with positioning the tile. Stand spacers on end. Do not place tile spacers flat at the intersection of tiles, they can become bonded, making it difficult to remove them without damaging the edge of the tile.

• Position two spacers along the edge of adjacent tiles, then lay the next tile gently against the spacers without forcing it into place (Fig. 10). Continue to set the tiles in straight rows to complete each section (Fig. 11). Follow the chalk lines to keep the joints straight and make minor adjustments if necessary. Remove the spacers immediately after setting each tile.

Ungrouted Floors

• When installing an ungrouted floor, continue setting the tiles in a stair-step pattern along the center and perpendicular lines (Fig. 12). Hold the tile in a low angle to the floor and position it tightly against the previously laid tile. Press it firmly into the adhesive. Continue working toward the walls to complete the first quadrant before starting the next. Check to make sure corners are lined up and adjust if necessary to prevent run-out.

• Spread the adhesive on the second half of the floor so it can dry while you are cutting and fitting the last row of tiles along the wall. Complete the second half of the room following the same procedures.

• Roll the floor slowly, in both directions, with a 100 lb., three-section roller within one hour after setting the tiles (Fig. 13). Re-roll the entire floor immediately before grouting or applying joint sealer.

The last row of tiles will need to be cut to fit to walls and other vertical surfaces. Allow a 1/8" space for expansion, between the edge of the tile and the wall. Remember to subtract the grout line dimension for grouted floors.

• Measure the distance between the last whole tile and the wall. Subtract the dimensions for the grout and expansion space. Use this dimension to mark the tile.

• Place a square or straightedge over the marks and score the surface with a sharp utility knife. Break the tile over the score mark by flexing it downward.

• Install the tile with the cut edge against the wall.

• Scribe the tile to fit.

Fig. 9 - Use spacers with one leg removed.

Fig. 10 - Position spacers before setting the tile.

Fig. 11 - Set tile in straight rows.

Fig. 13 - Roll the floor within one hour after setting tiles.

Fig. 12 - Install ungrouted floors following a stair-step pattern.

• Warm the tile with a hot air heat gun. Score the surface with a sharp utility knife and break the tile over the score mark by flexing it downward or cut the tile with a coping saw.

• Mark the location of the outlet on the tile.

• Score the surface with a sharp utility knife over the marks. Be careful not to extend the cut beyond the corners.

• Warm the tile with a heat gun and press firmly over the score mark to remove the center section.

Electrical outlets and light switches on walls and backsplashes must be turned off prior to spreading adhesive or grouting. Shut off breaker(s) or remove the fuse(s) to turn off outlets and switches in the work area. Remove the cover plate and place tape over the entire electrical box. Do not use adhesive, grout or water near live electrical outlets or switches. Keep outlets and switches dry during installation. Comply with all applicable building and electrical codes.

• Level

• Wall roller

• Protective drop cloth

• 1/4" nap smooth surface paint roller (optional)

DuraCeramic Options can be installed over painted dry wall or plaster, plywood, prepared ceramic or plastic laminate surfaces. The surface must be clean, dry and free of dust, dirt, grease or other extraneous material that will inhibit bonding. Deviations in the flatness of the wall surface cannot exceed 1/16" in 1’ or 3/16" in 10’. Check the surface with a straightedge and fill low areas with a portland cementbased latex patching compound. Gypsum-based patching compounds are not recommended.

• Painted drywall and plaster must be smooth, dry and clean. Bare drywall, plaster and gypsum compounds must be primed with a high-quality latex paint primer and allowed to dry for at least 48 hours. Existing surfaces must be thoroughly cleaned with a general purpose cleaner and water using a 3M white pad to remove all dirt and grease, and then rinsed thoroughly and allowed to dry completely. Check the surface for flatness with a straightedge and mark low areas with a pencil. Pay particular attention to unevenness at corners, window and door openings and joints in the wall board. Fill low areas with a portland cement latex patching compound. Set all protruding nails or screws flush with the surface.

WARNING: Do not sand painted surfaces.

Some paints in the past contained lead. These paints could be the surface coat or an underlying coat on the walls in older dwellings. Painted surfaces that are known to be free of lead can be lightly abraded with a mild abrasive cleaning pad and cleaning solution if necessary.

• Existing ceramic tile must be leveled with a portland cement patching compound following label instructions.

• Plastic laminate surfaces should be checked to make sure they are clean and securely bonded.

• 1/4" plywood underlayment can be installed in areas where the wall surface is unsuitable for covering. The underlayment should be secured with paneling adhesive and screws. The screws should be sufficient length to penetrate the wall studs by at least 3/4".

Walls and other vertical surfaces will need to be laid out using a level to stablish the horizontal and vertical center lines.

• Locate the center of the wall or area to be covered with tile in the height and width directions.

• Place the level over the center point and mark the wall with a pencil continuing the entire length of the wall (Fig. 14).

• Make a dry layout in a single row on the floor to check the size of the cut tiles at the perimeter. Adjust the horizontal and/or vertical lines one-half the distance of a tile if necessary to achieve a larger tile at the perimeter.

• Extend the horizontal line onto adjacent walls that will be covered so joints line up at the corners. When covering large surfaces, lay out additional reference lines to help keep joints running straight and establish sections for applying only enough adhesive that can be covered within the working time (Fig. 15).

Fig. 14 – Use a level to establish vertical and horizontal lines.

ADHESIVE APPLICATION WARNING:

See warning statement for shock hazards associated with tile installation near electrical outlets and switches. DS100 DuraSet Adhesive is recommended for all approved wall, backsplash and base applications. The tile must be set into the adhesive while it is in a semi tacky dry state to achieve maximum bond strength on a vertical surface. Do not set tile in tacky dry adhesive on walls or other vertical surfaces. Use a drop cloth to protect countertops and floors against adhesive spills. Apply DS100 adhesive on the wall, starting at the center lines with the recommended notched trowel or a 1/4" nap smooth surface paint roller at a coverage rate of 200 sf/gal. When using a roller, apply a coat of adhesive thick enough that it completely covers the surface with a light blue color. Do not go back over adhesive once the desired coat has been applied. Allow the adhesive to tack up for 20 to 30 minutes before setting the tile. The adhesive must be soft and sticky, not tacky dry when setting tiles on walls. Working time is 10 to 20 minutes under normal conditions, shorter in warm, dry conditions. Apply only enough adhesive that can be covered within the working time. Reapply fresh adhesive with the flat side of the trowel over adhesive that has been allowed to dry.

SETTING WALL TILES

Set the first tile along the center lines and press it firmly into place. Avoid squeezing adhesive into the joints. The adhesive should be soft enough that the tile can be adjusted slightly if needed, but will not slip when pressed firmly into place. Continue setting wall tiles in the semi tacky dry adhesive following the details for grouted tiles using a spacer and ungrouted tiles laid directly together. Complete each adhered section including cut pieces before adhesive dries completely to a tack. Spacers can normally be removed immediately. Roll each section with a wall roller using firm pressure immediately after setting tiles. Continue applying adhesive in small sections and setting tile to complete the wall. Re-roll the entire wall immediately after tiles are set and again just prior to grouting. The wall can be grouted immediately or within 24 hours.

PL Brand Polyurethane Construction Adhesive can be used as an alternative to DS100 for setting tiles on a vertical surface. This system provides a permanent bond and permits installation over a slightly rough or uneven surface.

• This adhesive does not have sufficient tack to prevent the tile from slipping so it will be necessary to secure a ledger strip to the wall before starting.

• Mark the wall at the bottom at the exact location where the last whole tile will end. Use a level to extend a pencilline along the entire wall at this point.

• Screw or nail a straight furring strip below the line to temporarily rest the first row against.

• Apply the PL Polyurethane Construction Adhesive directly onto the back of the tile. Apply a 1/8" bead of adhesive around the perimeter, about 1/2" in from the edge and place an "x" in the center of the tile.

• Install the tile within 10 minutes. Several pieces can be glued at one time and then installed quickly before a surface skin develops.

• Press each tile firmly into place with a slight back and forth shifting motion to flatten the adhesive beads. Use spacers to separate the tile joints on grouted applications. Leave the spacer in place only until the adhesive sets sufficiently to prevent tiles from slipping (2 to 4 hours). Roll the tile with a wall roller immediately after removing the spacers.

Important Instructions for Using Different Spacer Sizes When Combining DuraCeramic and DuraCeramic Options

-When installing custom installations that combine 16" x 16" formats with 8" x 8" formats, it will be necessary to use different size spacers to maintain straight joints. Tiles that have been scored and separated will have one additional grout line that needs to be calculated in the overall size (Fig. 16). To compensate for the additional grout joint, the separated tiles should be installed with a spacer that is one-half the thickness of the spacer used for the whole tiles (Fig. 17). The joints can be off-set on border tiles as an alternative to using different spacer sizes (Fig. 18).

-Consider layout and spacer size when creating a pattern with two different tile sizes. First determine the actual size of the pattern repeat in both directions, including the grout line width (Fig. 19). Adjust the center lines so the pattern is balanced in the room and the desired appearance is achieved (Fig. 20 A/B).

Fig. 15 – Lay out additional reference lines for alignment and adhesive application.10

-Use the measurement of the full pattern repeat to lay out additional chalk lines to keep joints straight (Fig. 21).

• Lay out the center and perpendicular lines as previously described for a square layout. Place a mark on each line an equal distance away from the center point (distance from center is arbitrary).

• Use a slightly larger arbitrary size and swing an arc on both sides of each line from points E, F, G, H (Fig. 22). Snap diagonal chalk lines at the point where the marks intersect. If done correctly, the chalk lines will intersect at the center point.

• Make a dry layout in one quadrant along the center and perpendicular chalk lines.

• Measure the distance between the last whole tile and the wall. If the distance in either row is less than one-forth of the diagonal dimension of the tile (whole tile = 5 1/2" and a separated tile = 2 3/4"), adjust the starting point and snap a new chalk line (use the dimension for the tile being installed) away from the original chalk line (Fig. 23). This will provide a balanced layout with larger cut tile around the perimeter.

Fig. 17 - Separated border tiles use a spacer one-half the thickness of the whole tiles.

Fig. 16 - Separated tiles will have one additional grout line.

Fig. 18- An alternative to using different spacer sizes is to off-set the joints.

Fig. 20 - Reposition the center lines so the separated tile (A) or the whole tile (B) is at the center of the room to achieve the desired border appearance.

Fig. 19- Determine the dimensions for the pattern repeat.

Fig. 21 - Lay out additional chalk lines the exact dimensions of the pattern

Fig. 22 - Diagonal layout.

Fig. 23 - Adjusting chalk lines for a diagonal layout.

Use a spacer 1/2 the gauge

Borders can be created easily by using an accent color or different size tile on a square layout. Plan the layout to allow for a uniform border size using full size tile in the field if possible. When using a square border with a diagonal layout, it is necessary to prepare the cut edge of the diagonal tile where it meets the border.

When installing tile with a diagonal layout and a square border, it will be necessary to prepare the cut edge of the diagonally cut tile. First cut the tile to the desired size. Then heat the cut edge and back of the tile with a heat gun to often it. Place the tile on a flat surface and roll the edge with a steel hand roller to turn the edge downward, forming a light radius (Fig. 24). Allow the tile to cool before installing it.

See warning statement for shock hazards associated with tile installation near electrical outlets and switches.

• DuraCeramic and DuraCeramic Options can be grouted immediately or within 24 hours after setting the tiles.

• Tiles must be grouted using DuraCeramic Premix Grout. This exclusive premixed acrylic grout is designed for high flexural strength and adhesion to the edge of the tile. This feature provides durability to resist cracking from thermal dimensional changes and normal subfloor deflection. Traditional cement grouts are not recommended and will not perform properly.

• Hard, green, rubber epoxy float

• Firm, square-edge sponge

• 3M® white nylon scrubbing pad

• Spray bottle of water

• Water buckets

• Rubber gloves

• Safety glasses

Soft grout floats and soft sponges are not recommended because they tend to pull the grout out of the joint, leaving it shallow.

• Re-roll the floor or wall just before grouting and check to make sure all edges are tightly seated in the setting adhesive. The joints must be clean and dry. Remove any adhesive smears from the surface and edges of the tile with mineral spirits before grouting.

• Start grouting floors at the far end of the room and work toward the entrance. Walls should be grouted starting at the bottom and working upward in narrow columns. This will reduce the possibility of water flowing into ungrouted joints during cleanup.

• Apply grout in small sections, up to 20 sq. ft. and cleanup immediately or before grout films over (approximately 5 minutes).

• Use the tip of a hard rubber float and fully pack the grout into the joints (Fig. 25). Hold the float in a low angle and press firmly with short strokes at a right angle to the joint.

• Extend the grout a few inches in to the next row of tile so water does not run into the unfinished joints during cleanup (Fig. 26).

• Remove excess grout from the surface of the tile by holding the float at a 45° angle to the floor surface and moving diagonally across the joints.

Fig. 24 - Roll the cut edge to form a slight radius.

Fig. 25 - Pack the grout into the joints.

Fig. 26 - Extend grout a few inches into the next row.

• Apply a light mist of water with the spray bottle over the grouted tiles and allow it to remain on the surface for at least 30 seconds.

• Use a slightly wet 3M white nylon pad to loosen the grout residue. Apply light pressure while moving the pad in a circular motion (Fig. 27).

• Use a firm square edge sponge to remove the excess water solution. Use light pressure and wipe diagonally across the joints (Fig. 28). Do not allow the water to flow into the ungrouted joints or accumulate in finished areas.

• Then rinse the sponge in clean water and wipe diagonally again to shape joints evenly and remove any remaining grout residue. Change rinse water frequently. Clean tools with water while grout is wet. If allowed to dry, remove with ammonia.

• Allow grout to dry for 24 hours.

• Remove any remaining grout haze with an ammonia-based window cleaner or a dilute solution of 1/4 cup household ammonia to one gallon of warm water. Apply a small amount of the solution over a small section and allow it to remain for about 30 seconds. Use a clean sponge mop or a 3M nylon white pad to loosen the grout haze. Rinse with fresh water and buff with a soft, dry terry cloth towel. Do not use grout haze removers or solvents.

• If touch up is necessary, new grout can be applied directly over existing grout.

Keep all traffic off newly tiled floors for 24 hours. Resume normal traffic after 48 hours. Joint Sealer Application

DuraCeramic DS200 Joint Sealer is designed to keep surface water and dirt from penetrating ungrouted floor joints. Do not use joint sealer on walls, other vertical surfaces or apply to the embossed center lines on DuraCeramic Options when installing a full 16" x 16" format. Apply joint sealer to the tile joints only.

• Roll the floor with a 100 lb., three-section roller just before sealing the floor and check to make sure all edges are tightly seated in the setting adhesive. The joints must be clean and dry. Remove any adhesive smears from the surface and edges of the tile with mineral spirits before sealing. Vacuum the floor to remove dust and loose particles.

• Shake the applicator bottle and allow air bubbles to dissipate before using.

• Remove the plastic cap and screw the applicator tip onto the bottle.

• Cut 1/16" off of the applicator tip to provide a small opening.

• Start in the far corner of the room and apply a uniform 1/16" bead of sealer in the tile joint. Apply the sealer to the first 2 or 3 rows, then come back immediately and seal the perpendicular (cross) joints in this area before the sealer develops a surface film (about 4 minutes). Repeat this process to seal the entire floor.

• The color of the sealer will change from white to clear when it dries.

• If the nozzle becomes clogged, use a straight pin to free the flow.

• Protect newly applied joint sealer from foot traffic and dust until it dries, (approximately 8 hours). Keep traffic to a minimum and do not wash the floor for the first 48 hours.

• Use water cleanup for wet sealer and mineral spirits for dry sealer. Caution: Mineral spirits is flammable. Read and follow label instructions.

-Install or replace base moldings and return furniture to the room by rolling or sliding them over strips of hardboard.

-Use acrylic caulking at bathtubs, showers and other wet areas to prevent water from seeping under the floor.

-Wait 48 hours before damp mopping the floor and at least 5 days before wet mopping or washing. Adhesive smears can be removed with mineral spirits.

DuraCeramic and DuraCeramic Options can be repaired easily if it is necessary to replace a tile.

• Use a heat gun to warm the grout along one edge of the tile. The grout will soften when heated.

• Place a straightedge over the center of the grout line and cut the grout with a sharp utility knife (Fig. 29).

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Fig. 27 - Use a 3M white, nylon pad to loosen grout residue.

Fig. 28 - Wipe diagonally across the joints to remove excess water.

• Remove as much of the grout as possible using care to avoid cutting into the edge of the adjacent tile. Repeat this process on all four sides of the damaged tile.

• Next, heat the tile a few inches in from the corner. While the tile is warm, drive a putty knife or screwdriver into the heated area with a hammer (Fig. 30).

• Then, pry upward to release the tile from the adhesive. Continue lifting the tile as you heat it until it is completely removed.

• To install the new tile, re-apply DS100 DuraSet Adhesive over the exposed subfloor using the flat side of a trowel; it is not necessary to remove the old adhesive.

• Allow the adhesive to dry completely to a tack and then reinstall the new tile using spacers to maintain the grout line width.

• Roll the tile with a 100 lb., three-section roller.

• Re-grout the tile with DuraCeramic Grout following label instructions. Allow grout to dry for 24 hours and remove any remaining grout haze.

• Use a utility knife and carefully cut through the joint sealer using care to avoid cutting into the adjacent tiles.

• Follow the same procedure for Grouted Floors to remove the tile and re-adhere the replacement tile.

• Re-apply DuraCeramic DS200 Joint Sealer along all four sides of the tile to seal the joints.

-Make sure furniture legs have large surface, nonstaining floor protectors. Replace small, narrow metal or domeshaped glides with smooth, flat glides that are in flat contact with the floor. Glides should be equipped with self-adhesive felt pads to avoid scratching the surface of the floor. The pads should be checked periodically for grit and wear and replaced when necessary.

-Heavy furniture or appliances that are not moved often should be equipped with flat, nonstaining compositionfurniture casters or cups of appropriate size - available square from 1 1/2" to 2 5/8" and round from 1 3/8" to 1 5/8".

-Mobile appliances and furniture should be equipped with easily swiveling casters. They should be at least 2" in diameter with nonstaining hard rubber treads at least 3/4" wide. Do not use ball-shaped casters.¡ Place mats at outside entrances to prevent dirt, grit and soil from being tracked onto the floor.

CAUTION: DuraCeramic, like other types of hardsurfaced floors, can become slippery when wet. Allow time for the floor to dry after washing. Immediately wipe up wet areas from spills or wet feet. Place mats at outside entrances to prevent water, snow or ice from being tracked onto the floor. Improper polishes or finishes can also cause slipperiness.

-Sweep or vacuum regularly to remove grit and sand that can abrade, dull or scratch the new floor. Do not use a vacuum with a beater brush, because it may damage the floor’s surface.

-Wipe up spills promptly with a damp cloth or mop.

-Wash the floor with Congoleum Bright ’N Easy No-Rinse Cleaner or other suitable floor cleaner.

CAUTION: Avoid one-step "mop and polish" products, dishwashing liquids and oil-based cleaners. These may leave a residue which can attract dirt and dull the floor’s finish. Avoid cleaners that contain abrasives or solvents which may permanently damage the floor.

• Do not use acrylic or silicone sealers or penetrating sealers on the tile surface. A copolymer or acrylic grout sealer compatible with acrylic grouts may be used on the grout. Do not use a penetrating silicone sealer on the grout.

• The use of floor polish is optional. Light commercial areas that receive a high concentration of traffic or more frequent spills can be maintained with Congoleum Commercial Satin-Gloss Polish (C3100) for added protection. Do not buff the floor.

For additional care information contact:

Congoleum Corporation Dept. C

3500 Quakerbridge Road

P.O. Box 3127

Mercerville, NJ 08619

1-800-274-3266

www.congoleum.com13