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Terracotta Flooring and Paving

Pica Cotto Floor Tiles Manual

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Page 1: Pica Cotto Floor Tiles Manual

Terracotta Flooring and Paving

Page 2: Pica Cotto Floor Tiles Manual

Terracotta Flooring And PavingFlooring And Paving•Technical/commercial classification

•Classification according to UNI EN standards

UNI EN 87

UNI EN 187 product requirements

Test methods

Laying The Tiles•Functional layers

•Compatibility between tiles and subgrade

Expansion joints

Drainage and removal of water

•Bedding layer

Laying techniques using mortar or adhesives

Terracotta outdoors

•Sealing the joints

Treatment•Cleaning

•Protection

•Finishing and maintenance

•Treatment diagrams

Troubleshooting

Specific notes about our flooring and paving

Conclusions and discussion

Page 3: Pica Cotto Floor Tiles Manual

Flooring And Paving

Page 4: Pica Cotto Floor Tiles Manual

Introduction: Flooring and Paving

Ceramic tiles – Technical/commercial classification

In Italy there are technical/commercial classification standards - currently employed

by manufacturers and users of ceramic tiles alike - based on various technical and

technological characteristics.

These classification standards list the different types of tile according to:

Surface layer

(glazed or not glazed)

Water absorption

(linked to porosity)

Moulding method

(pressing or extrusion)

Main destination

(floor or wall coverage, interior or exterior)

Page 5: Pica Cotto Floor Tiles Manual

Introduction: Flooring And Paving

Ceramic tiles – Technical/commercial classification

Type Water

absorption (%)

Moulding

method

Main use

•Glazed surface

Majolica

Earthenware

White body single-fired

tiles

Red single-fired tiles

Klinker

15-25

7-15

0-6

0-15

0-6

Pressing

Pressing

Pressing

Pressing

Extrusion

Indoor coverage

Indoor flooring

Outdoor paving/Indoor flooring

Outdoor paving/ Indoor flooring

Outdoor paving/Outdoor

coverage/Indoor flooring

•Unglazed surface

Terracotta

Red stoneware

Fully vitrified stoneware

Klinker

3-15

0-4

0-0.5

0-6

Extrusion

Pressing

Pressing

Extrusion

Indoor flooring/Outdoor paving

Outdoor paving/Indoor flooring

Out. paving/Ind.floor./ Out.cover.

Out. pav./Ind. floor./Out.cover.

It should be pointed out, however, that following technological and system

developments occurring in the ceramic tile industry over the last few years, the

classification shown here has begun to reveal a few limitations in terms of its

representativeness, above all with regard to single-fired tiles, which now include

several specific products that are the results of new technology.

Page 6: Pica Cotto Floor Tiles Manual

Introduction: Flooring And Paving

Classification according to EN standards

As well as technical-commercial classifications, there is a further and no less

important means of classification. It is the classification for ceramic tiles as laid

down in the European Norms, published in Italy with the UNI EN mark.

The UNI EN 87 standard is the basic norm containing the classification, definitions

and characteristics for ceramic tiles.

It is an extremely simple, schematic classification, since it is based on just two

parameters, which are:

Water absorption

Moulding method

The European norms being completed with the publication and implementation of

the EN standards in the single states, it then became necessary to establish

standards to be applied at world level (ISO standards), to overcome, for example,

the differences existing between the EN European standards and American ANSI

standards.

The fundamental framework of ISO standards was developed starting with the

current European standards and it includes several variations in test methods as

well as stricter parameters in some cases.

Page 7: Pica Cotto Floor Tiles Manual

Introduction: Flooring And Paving

Classification according to EN standards

Forming method Water absorption, WA (%)

I

WA ≤ 3

IIa

3 < WA ≤ 6

IIb

6 < WA ≤ 10

III

WA > 10

Extruded tiles

Pressed tiles

AI

UNI EN 121

AIIa

UNI EN 186

AIIb

UNI EN 187

AIII

UNI EN 188

BI

UNI EN 176

BIIa

UNI EN 177

BIIb

UNI EN 178

BIII

UNI EN 159

A

B

The tiles in the A groups are extruded, while those in the B groups are

pressed.

I groups are those with the lowest level of porosity, while III groups have a

higher level of porosity.

The standard also establishes 8 product standards, indicating different

requirements that must be met by the tiles in that group.

Page 8: Pica Cotto Floor Tiles Manual

Introduction: Flooring And Paving

Classification according to EN standards

Ge

nera

l

Standard Subject

EN 87

EN 163

Definitions, classification, characteristics and markings

Sampling and acceptance criteria

Pro

du

ct

Req

uire

me

nts

EN 121

EN 159

EN 176

EN 177

EN 178

EN 186

EN 187

EN 188

Extruded ceramic tiles with low water absorption…

Dry pressed ceramic tiles with high water absorption…

Dry pressed ceramic tiles with low water absorption…

Dry pressed ceramic tiles with water absorption…

Dry pressed ceramic tiles with water absorption…

Extruded tiles with water absorption…

Extruded tiles with water absorption (6%<WA≤10%)

Extruded tiles with high water absorption…

Te

st M

eth

od

EN 98

EN 99

EN 100

EN 101

EN 102

EN 103

EN 104

EN 105

EN 106

EN 122

EN 154

EN 155

EN 202

Dimensional and appearance characteristics

Water absorption

Bending strength

Surface hardness according to MOHS scale

Deep abrasion resistance for unglazed tiles

Linear thermal expansion

Thermal shock resistance

Crazing resistance

Chemical resistance – unglazed tiles

Chemical resistance – glazed tiles

Surface abrasion resistance for glazed tiles (PEI)

Moisture expansion using boiling water

Frost resistance

… 13 test methods have also been defined.

Page 9: Pica Cotto Floor Tiles Manual

Laying The Tiles

Page 10: Pica Cotto Floor Tiles Manual

Laying The Tiles: Functional Layers

Tiles form the surface finish of a more complex building system: the floor.

This system is formed by different layers, each of which is usually comprised of

a different material.

For this reason, before laying the tiles, it is advisable to look at greater depth at

the surfaces on which they are to be installed.

Page 11: Pica Cotto Floor Tiles Manual

Laying The Tiles: Functional Layers

Covering layer

Bedding layer

Levelling layer

Reinforcement or

load-bearing layer

Separation or floating

layer

Thermal insulation layer

Damp-proofing layer

Load-bearing layer

List and graphic symbols of the functional layers that form a floor.

Page 12: Pica Cotto Floor Tiles Manual

Laying The Tiles: Functional Layers

Covering layer

This is formed by tiles and, as already

mentioned, its function is to provide a

surface finish.

This layer must be designed and installed

so as to guarantee conformity with the

following requirements:

Regularity

Completeness and durability

Safety

Bedding layer

The function of this layer is to connect the

tiles to one another and to make them

adhere to their supporting surface.

It may be formed using cement mortar,

adhesive or aggregate.

Page 13: Pica Cotto Floor Tiles Manual

Laying The Tiles: Functional Layers

Levelling layer

This layer serves to absorb errors in

support surface flatness and to eliminate

any surface unevenness or irregularities.

It is also used to house piping, if any.

It is generally made using cement-based

binders.

Reinforcement or load-bearing layer

If there are other compressible layers, this

one serves to prevent any break-up in the

covering layer caused by the compressible

nature or in other words, pliability, of these

layers.

Most of the time, it is formed by a

foundation in concrete, reinforced by

electrically welded mesh.

Page 14: Pica Cotto Floor Tiles Manual

Laying The Tiles: Functional Layers

Separation or floating layer

The purpose of this layer is to chemically,

physically or mechanically separate one

layer from another.

Generally, polyethylene film is used.

Thermal insulation layer

This layer serves to check the flow of heat

through the flooring in order to limit energy

consumption.

It is possible to use thermal insulation

materials, which are available in sheets

(cork, polyurethane foam or polystyrene),

or blocks in lightweight concrete (made

with expanded clay, vermiculite or

pearlite).

Page 15: Pica Cotto Floor Tiles Manual

Laying The Tiles: Functional Layers

Damp-proofing layer

This serves to prevent the passage of

water to the underlying layers and areas.

Polyethylene film is generally used for

damp proofing.

Load-bearing layer

This is the structure to be clad and its

function is to transfer its loads and the

load to which the floor is subjected to the

vertical static load structures.

These structures are generally floors in

concrete and masonry or in reinforced

concrete cast in situ, etc.

For exteriors, it is natural earth.

Page 16: Pica Cotto Floor Tiles Manual

Laying The Tiles: Compatibility Between Tiles And Subgrade

Expansion joints

>From a size point of view, tiles have a rather fine thickness (approximately 15 -

16 mm for terracotta tiles).

From a mechanical viewpoint, they are rigid, or in other words, they cannot

deform to any great degree and, if subjected to mechanical stress, they will break

once their elastic deformation range has been exceeded.

This fact gives rise to several requirements:

In the first place, it means that the covering layer formed by the tiles needs the

solidarity and mechanical collaboration of another layer of sufficient size (thickness)

to which it must be stably connected in such a way as not to place the covering in a

condition to suffer breakage on account of pressing or deflection.

Secondly, the conditions bonding the covering layer to the underlying layers must

be such that they prevent negative interference from any differential movements

among the layers themselves, caused by thermal or hygrometric expansion or by

the dimensional contraction of the cement layers due to the shrinkage that

accompanies setting.

Page 17: Pica Cotto Floor Tiles Manual

Laying The Tiles:

Expansion joints

Every material has its own thermal expansion coefficient and therefore, it

responds to a given change in temperature with a different variation in its

dimensions.

It must be taken into account that the layers of which the system is comprised are

not free to move, since they are joined to one another in different ways; they are

bound and therefore, any change in temperature invariably leads to tension.

All types of structures have joints between adjacent sections to allow relative

movements, although these may be limited, between one part and another.

It is important to know the location, extension and size of these joints, since

they must also be inserted in the bedding and covering layers.

Example of an expansion joint.

www.folotec.com

Compatibility Between Tiles And Subgrade

Page 18: Pica Cotto Floor Tiles Manual

Laying The Tiles:

Expansion joints

The form of the surfaces to be covered and the variable given by indoor

flooring or outdoor paving, have a determining influence on the choice of where

and how to install the expansion joints. These joints can in turn influence the

choice of tile format, layout and choice of laying technique.

Indoor flooring:

For small-sized rooms, it is sufficient to insert a joint on the outer perimeter of the

room; for larger areas, it is advisable to insert a joint approximately every 7 metres,

both lengthways and crossways.

Moreover, to reduce tension, it is advisable to insert a floating layer between two

layers (bedding layer and load-bearing layer).

Low-density polyethylene film is usually used for interiors.

Compatibility Between Tiles And Subgrade

floating layerPerimeter joint

Page 19: Pica Cotto Floor Tiles Manual

Laying The Tiles:

Expansion joints

Outdoor paving:

Insert expansion joints, with good-quality rubber profiles, approximately every 4 – 5

metres, both lengthways and crossways, above all for paving over large areas or

laid in areas with a high degree of thermal movement.

Firstly, it is necessary to check for the presence of structural joints (foundation); if

not present, it will be necessary to isolate the reinforcement layer and load-bearing

layer from the bedding layer by inserting a floating layer.

Geotextiles are normally used out of doors. As well as reducing the tension

between the two layers, these geotextiles will not limit the drainage action of the

subgrade.

If the foundation already has expansion joints, they

must also be installed in the bedding and covering layers.

If there are no structural joints in the foundation,

it is necessary to insert a floating layer (geotextile)

beneath the bedding layer.

Compatibility Between Tiles And Subgrade

Geotextile layer

Page 20: Pica Cotto Floor Tiles Manual

Laying The Tiles:

Drainage and removal of water

Each layer is required to fill an exact function and it is most important to be

aware of the way in which they interact with the surface. In fact, terracotta

belongs to the category of so-called “pure” materials that will sooner or later

show any problems that might originate from long before the tiles were laid.

Out of doors, most of these problems are linked to standing water or

damp in the subgrade.

For this reason, it is necessary to install drainage systems to allow water

dispersion and sloped floating surfaces to keep water away.

Compatibility Between Tiles And Subgrade

First of all, it is necessary for the screed to be even;

highly uneven screeds are extremely damaging

because they make it impossible to create a laying bed

with a constant thickness. This leads to the build up of

damp, which then causes the formation of

efflorescence and marked differences in expansion

coefficients.

These conditions can lead to tile breakage and

crumbling.

Example of a non-flat laying bed.

Page 21: Pica Cotto Floor Tiles Manual

Laying The Tiles: Compatibility Between Tiles And Subgrade

Drainage and removal of water

Outdoor paving subject to pedestrian traffic

Laying terracotta blocks using the “dry” or “semidry” method

Terracotta blocks

0.3 sand

Bedding layer- 3-6 mm grit

Geotextile

(20 –25 mm stabilised

Levelling foundation with a slope of 1.5 - 5% -

concrete dosed for 1 quintal of cement

Load-bearing layer – Natural earth

Page 22: Pica Cotto Floor Tiles Manual

Laying The Tiles: Compatibility Between Tiles And Subgrade

Drainage and removal of water

Terracotta blocks

0.3 sand

Bedding layer - 3-6 mm grit

“Filter – drainage – protection “ system

Geotextile + Drainage cuspidate membrane

Reinforcement and load-bearing layer with a

slope of 1.5 – 5% _ Foundation in concrete

dosed for 3 quintals of cement + electrically

welded mesh Ø6 / 8mm.

Loose stone foundation

Load-bearing layer – Natural earth

Outdoor paving subject to vehicle traffic

Laying terracotta blocks using the “dry” or “semidry” method

Page 23: Pica Cotto Floor Tiles Manual

Laying The Tiles: Compatibility Between Tiles And Subgrade

Drainage and removal of water

“Filter – drainage – protection” system _ Composite TENAX DP 1

The composite is formed by two

distinct, integral structures,

heat-welded together.

a) An extruded protective,

drainage membrane in high-

density polyethylene (HDPE),

with a high degree of

compressive strength and

impenetrable at the roots,

characterised by a flat face

which must be placed in contact

with the screed or damp

proofing, and by a cuspate face.

b) An unwoven filtering geotextile

in polypropylene (PP), joined to

the mesh level with the tips of

the cusps.

Page 24: Pica Cotto Floor Tiles Manual

Laying The Tiles: Compatibility Between Tiles And Subgrade

Drainage and removal of water

Outdoor paving subject to pedestrian and/or vehicle traffic

Laying terracotta tiles with the “mortar” or “adhesive” technique

Terracotta paving, slope 1.5 – 2%

Sand and cement grout or ready-mixed seal

Bedding layer _ 6-8 cm foundation

using 1.5 quintals of cement and 0.3

sand (alternatively, adhesive)

Reinforcement and load-bearing layer with 1.5 – 5%

slope _ Foundation in concrete dosed for 3 quintals

of cement + electrically welded mesh Ø6-8mm

Foundation in loose stone/Lean concrete dosed for

1 quintal of cement

Load-bearing layer _ Natural earth

Separation or floating layer - geotextile

Page 25: Pica Cotto Floor Tiles Manual

Laying The Tiles: Compatibility Between Tiles And Subgrade

Drainage and removal of water

Terracotta paving, slope 1.5 – 2%

Foundation, slope 1.5 – 5%

Waterproof sheath

Load-bearing layer – Floor in reinforced concrete

Grout in sand and cement or ready-mixed

seal

Bedding layer_Adhesive

Levelling layer_foundation, slope 1.5 – 2%

Correct damp proofing for a balcony _ 1

Page 26: Pica Cotto Floor Tiles Manual

Laying The Tiles: Compatibility Between Tiles And Subgrade

Drainage and removal of water

Terracotta paving, slope 1.5 – 2%

Double layer of waterproof mortar, reinforced

with fibreglass mesh

Foundation, slope 1.5 – 2%

Waterproof sheath

Load-bearing layer – Floor in reinforced concrete

Grout in sand and cement or ready-mixed

seal

Bedding layer_Adhesive

Correct damp proofing for a balcony _ 2

Page 27: Pica Cotto Floor Tiles Manual

Laying The Tiles: Compatibility Between Tiles And Subgrade

Drainage and removal of water

Elastic cement-based bicomponent mortar to damp proof

concrete foundations _ MAPELASTIC

This is a cement-based

bicomponent mortar containing

selected, fine-grain aggregates

and synthetic polymers.

(powder + liquid).

The mortar is laid with a flat

trowel to a maximum thickness

of 2 mm per layer.

Before laying the second layer –

approximately 4-5 hours from

the first application – it is

advisable to insert low-weight

fibreglass mesh between the

two to prevent any microscopic

cracks and to distribute loads

evenly.

Page 28: Pica Cotto Floor Tiles Manual

Laying The Tiles: Compatibility Between Tiles And Subgrade

Drainage and removal of water

Flooring in underground rooms

Grout in sand and cement or ready-mixed

seal

Bedding layer_Adhesive

Thermal insulating subgrade _Foundation

in lightweight concrete using expanded clay

Foundation in loose stone/Lean concrete dosed

for 1 quintal of cement

Load-bearing layer _ Natural earth

Terracotta flooring

Waterproof sheath

Floating layer_polyethylene film

Levelling layer_foundation

Page 29: Pica Cotto Floor Tiles Manual

Laying The Tiles: Bedding Layer

“Mortar” laying technique

1. Clean the laying bed, removing any dust, debris and oily residues.

2. Spread an even layer of mortar, also known as the “foundation”, no less than 5 cm thick.

3. Sprinkle the surface with a fine covering of cement powder.

4. Begin to lay the tiles on this surface, taking care to maintain the direction of the dod

(the cut side of each tile should always correspond to the same side of the adjacent tile).

5. Leave a space between tiles. The width of this space, known as the ”grouth width” or

“joint”, is to be agreed with the Director of Works and in any case, it should be no less

than 3 mm or more than 10 mm.

6. The flooring should have expansion joints that can compensate for dimensional variations

caused by thermal movements. In the case of small areas, it is sufficient to insert a joint

along the outer perimeter of the room. For larger areas, it is advisable to insert a joint

approximately every 7 metres, both the lengthways and crossways.

7. Tamp the floor evenly to ensure better tile adherence to the mortar bed.

Page 30: Pica Cotto Floor Tiles Manual

Laying The Tiles: Bedding Layer

“Adhesive” laying technique

Laying with adhesives is not substantially different from laying with mortar, although it does

have the advantage of significantly reducing the waiting times required for the floor to dry

perfectly, which is an indispensable condition for passing on to the following stages.

1. Make sure that the structural floor is perfectly level.

2. Using a suitable trowel, spread an even layer of adhesive over the surface.

3. Lay the tiles before a film begins to form on the surface of the adhesive due to contact

with the air (which means that the drying process has begun).

4. Leave a space of at least 3 mm and no more than 10 mm between the tiles.

5. Ensure that the flooring has the necessary expansion joints to compensate for dimensional

variations caused by thermal movements. Follow the same precautions used for laying with

mortar.

It is now possible to buy specific adhesives for high-thickness cotto tiles, while normal

adhesives can be used for cotto tiles of lower thickness.

However, it is preferable to use adhesives containing hydraulic binders over those

containing synthetic resins only. Fast-setting adhesives should be avoided

(especially on floorings that have been pre-waterproofed).

Page 31: Pica Cotto Floor Tiles Manual

Laying The Tiles: Bedding Layer

Adhesives with hydraulic binders

Recommended for use with:

Cotto Rustico Indoors Outdoors (with added ISOLASTIC)

Cotto Linea Casato Indoors

Cement-based, adhesive powder for

ceramic tiles (adhesive thickness

up to 5 mm).

Technical Data (at +23°C and 50% R.H.):

POT LIFE: more than 8 hours.

OPEN TIME: approx. 20 minutes.

ADJUSTMENT TIME: approx. 45 minutes.

PRACTICABLE: after 24 hours.

READY FOR USE: 14 days.

GROUTING: walls 4-8 hours, floors 24 hours.

FLEXIBLE: no.

AVAILABLE COLOURS: grey and white.

COVERAGE: 2-5 kg per sq. m.

APPLICATION: notched trowel (no. 4, 5, or 6

according to use).

PACKAGING: 25 kg bags, 4x5 kg boxes.

Applications:

Adhesive for indoor and outdoor fixing

of ceramic tiles and mosaics of all types

on walls, floors and ceilings on traditional

supports (cement renders and screeds,

brick and block walls, etc.) as long as they

are solid, stable and clean.

It can be mixed with ISOLASTIC to obtain

an elastic adhesive.

Page 32: Pica Cotto Floor Tiles Manual

Laying The Tiles: Bedding Layer

Adhesives with hydraulic binders

Recommended for use with:

Cotto Pratico/Protetto Indoors Outdoors (with added ISOLASTIC)

Cotto ProntoZoni Indoors Outdoors (with added ISOLASTIC)

Cotto Fatto a Mano Indoors Outdoors (with added ISOLASTIC)

(Handmade Cotto)

Cement-based, adhesive powder for

ceramic tiles (adhesive thickness

up to 15 mm).

Technical Data (at +23°C and 50% R.H.):

POT LIFE: more than 8 hours.

OPEN TIME: approx. 20-30 minutes.

ADJUSTMENT TIME: approx. 45 minutes.

PRACTICABLE: after 24-36 hours.

READY FOR USE: 14 days.

GROUTING: walls 6-8 hours, floors 24-36 hours.

FLEXIBLE: no.

AVAILABLE COLOURS: grey and white.

COVERAGE: 4-10 kg per sq. m.

APPLICATION: notched trowel (no. 6 or 10, or

trowel for KERAFLOOR according to use).

PACKAGING: 25 kg bags.

Applications:

Adhesive for indoor and outdoor bonding

of ceramic tiles and strip tiles with deep

recessed, profiled undersides, large formats,

cotto toscano, and natural stone, to walls,

floors and ceilings on traditional supports

(cement screeds), as long as they are

solid, stable and clean. It can be mixed

with ISOLASTIC to obtain an elastic adhesive.

It can be used to fix tiles to irregular substrates

with beds up to a thickness of 15 mm,

without prior levelling.

For large formats with deep profiles and

recesses, back-buttering is required.

Page 33: Pica Cotto Floor Tiles Manual

Laying The Tiles: Bedding Layer

Adhesives with hydraulic binders

Recommended for use with:

Cotto Rustico Outdoors

Cotto Pratico/Protetto Outdoors

Cotto ProntoZoni Outdoors

Outdoor Pavings and Décor Outdoors

Applications:

Adhesive for indoor and outdoor bonding of

ceramic tiles of all types (earthenware,

single-fired, vitrified stoneware, etc.)

to walls and floors on:

-Traditional supports (cement renders

and screeds, brick and block

walls, etc.).

-Old floors and coverings (ceramic, stone,

paving tiles, cement) as long as they are solid

and clean.

- Cast concrete, prefabricated concrete

panels, as long as sufficiently cured (6 months),

heating panels, cement-fibre panels, plasterboard,

wood or sufficiently bonded derivatives, and tiles

no larger than 300 sq. cm.

Technical Data (at +23°C and 50% R.H.):

POT LIFE: approx. 8 hours.

OPEN TIME: approx. 30 minutes.

ADJUSTMENT TIME:: approx. 60 minutes.

PRACTICABLE: after 24 hours.

READY FOR USE: 14 days.

GROUTING: walls 24 hours, floors 48 hours.

FLEXIBLE: good level.

AVAILABLE COLOURS: grey and white.

COVERAGE: 2.5 -4 kg per sq. m.

APPLICATION: notched trowel (no. 4. 5 or 6).

PACKAGING: 25 kg bags.

Medium-elasticity, adhesive powder for

ceramic tiles (adhesive thickness

up to 5 mm).

Page 34: Pica Cotto Floor Tiles Manual

Laying The Tiles: Bedding Layer

Terracotta outdoors

Cotto paving is able to withstand freezing and thermal movements. However, it is advisable

to adopt a few additional precautions to prevent any problems that could occur in extreme

conditions to alter the perfect finished look of the paving.

Laying the tiles

1. Tiles should be laid in mild weather, with temperatures ranging between 10 and 25 degrees.

2. Wet the tiles before laying, whether using the “mortar” or “adhesive” technique.

3. Make sure that the tiles adhere perfectly to the substrate and that there are no cavities in the

mortar bed or layer of adhesive. Any air pockets could lead to an accumulation of moisture

and, at extremely low temperatures, cause the tiles to come unstuck from their foundation.

4. Avoid laying the paving on structures (screeds) that have not settled definitively. Mechanical

stress caused by settling can cause serious cracking in the paving.

5. Insert expansion joints, with good-quality rubber profiles, every 4-5 metres, both lengthways

and crossways, especially in the case of large areas of paving or areas with a great deal of

thermal movement.

Page 35: Pica Cotto Floor Tiles Manual

Laying The Tiles: Bedding Layer

Terracotta outdoors

6. Prevent damp and salts from rising from the adjacent or underlying ground by:

• avoiding direct contact between the terracotta and soil or grassy surfaces, laying the tiles a

few centimetres higher than any adjacent lawn

• ensuring that the screed floor has the proper drainage

• insulating the paving from areas of standing water, such as swimming pools, gutters, etc. with

waterproof sheaths

• taking care to fill the joints evenly and without cracks.

7. Prevent moisture from collecting on the paved surface by:

• giving the paving a suitable slope (at least 1.5%) for the perfect run-off of rainwater

• ensuring that the paving is perfectly flat (no dips)

• making sure that the paving is perfectly aired all year round (be careful with the nylon

sheeting used to cover swimming pools during the winter; place some strips of wood, or a

thick-fibre material such as sacking between the tiles and the sheet to guarantee air

circulation).

8. Prevent moisture from collecting beneath the paved surface. If using sheathing (terraces,

porches, etc.) this should allow water to run off, creating a sufficient slope on the screed (at

least 2%) and using materials that allow drainage.

Page 36: Pica Cotto Floor Tiles Manual

Laying The Tiles: Sealing The Joints

Introduction

The shape and width of joints, the composition of the grout and the colour used for

the joints themselves are areas which, if neglected, can adversely affect

installation and final treatment.

As the width of the joints increases, this means that the composition of the sand

and cement mortar needs to be changed to include more sand. Therefore, a grout

width of more than 5 mm will always be rougher and grainier, but above all, it will

also be:

More absorbent and absorb in a less even manner

The main vehicle for infiltration and rising damp

An area where dirt is trapped therefore, making cleaning more difficult

Less receptive to treatment and finishing products

( since they are developed for the cotto itself and are therefore less suited to grouting).

As a result, finished appearance and personal tastes aside, technically, the most

functional joint is below 7 mm in width.

Page 37: Pica Cotto Floor Tiles Manual

Laying The Tiles: Sealing The Joints

Traditional grout

Joints less than 3 – 4 mm wide:

This grout is made by mixing normal 325 grey cement in water

Joints between 5 and 10 mm wide:

This grout is made by mixing 100 litres of fine, well-washed silica sand and 60 –

80 kg of 325 cement in water

It is good practice to wet the surface before spreading the grout; the setting time

will be slightly longer but the end result will be firmer and deeper.

Ready-mixed seals

It is preferable to use products that contain no synthetic resins or polymers. In

fact, these substances tend to penetrate the natural pores in the terracotta,

especially around the edges, causing stains that cannot be removed.

It is advisable to avoid using markedly coloured products (black, anthracite,

etc.). In fact, these products are quite difficult to remove once they have anchored

to the tile surface and penetrated it slightly – so much so, that in some cases, the

intervention of flooring specialists is required.

Page 38: Pica Cotto Floor Tiles Manual

Laying The Tiles: Sealing The Joints

Ready-mixed seals

Do not use!

Modified with polymers

and synthetic resins

OK!

Fast-setting and drying cement-based

grout for joint widths from 2 to 20 mm

USE

Interior and exterior grouting on walls and floors

in all types of ceramic tiles (earthenware, single-

fired, clinker, vitrified stoneware, terracotta, etc.),

glass mosaics, natural stone, marble mosaics,

reinforced concrete and glass tiles, etc.).

Specially recommended when fast flooring use

is required.

Does not produce calcium hydroxide

efflorescence.

Technical Data (at + 23°C and 50% R.H.):

POT LIFE: 30-45 minutes.

MIXING RATIO: from 20 to 26 parts water to every

100 parts ULTRACOLOR, according to the colour.

GROUTING AFTER INSTALLATION

walls: normal adhesive 3-4 hours; fast-setting adhesive

1-2 hours; traditional application 2-3 days;

floors: normal adhesive 24 hours; fast-setting adhesive

3-4 hours; traditional installation 7-10 days.

PRACTICABLE: approx. 3 hours.

READY FOR USE: 24 hours.

COLOURS: 24.

APPLICATION: rubber trowel.

RESISTANCE TO MOISTURE: excellent.

RESISTANCE TO SOLVENTS, OILS, AND

ALKALIS: excellent.

RESISTANCE TO ACID: poor.

PACKAGING: 25, 5 and 1 kg bags.

USE

Interior and exterior grouting on walls and floors

in all types of ceramic tiles (earthenware, single

fired, clinker, vitrified stoneware, terracotta, etc.),

glass mosaics, natural stones, marble mosaics,

reinforced concrete and glass tiles, etc.).

Cement-based grout for joint widths

from 0 to 4 mm (KERACOLOR FINE) and

from 5 to 15 mm (KERACOLOR GROSSO).

Technical Data (at + 23°C and 50% R.H.):

POT LIFE: approx. 2 hours

GROUTING AFTER INSTALLATION

walls bonded with normal adhesive 4-8 hours;

walls bonded with mortar 2-3 days;

floors bonded with adhesive 24 hours;

walls bonded with mortar 7-10 days.

PRACTICABLE: 24 hours.

READY FOR USE: 5 days.

FLEXIBLE: no.

COLOURS: 8.

COVERAGE: according to tile and joint size.

APPLICATION: rubber trowel.

RESISTANCE TO MOISTURE: excellent.

RESISTANCE TO SOLVENTS, OILS, AND

ALKALI: excellent.

RESISTANCE TO ACID: poor.

PACKAGING: 25- 22 and 5 kg bags according to colour.

Page 39: Pica Cotto Floor Tiles Manual

Laying The Tiles: Sealing The Joints

Ready-mixed seals _ KERACOLOR colour range

MANHATTAN TITANIUM CEMENT ANTHRACITE BLACK

CHAMPAGNE ANEMONE BAHAMABEIGE

BAHAMABEIGE BROWN

No! No!

Page 40: Pica Cotto Floor Tiles Manual

Laying The Tiles: Sealing The Joints

Pre–waterproofing

For materials with a high degree of absorption or, if the stylistic choice means

opting for a markedly coloured seal, it is necessary to clean the floor surface

briefly and to apply the correct doses of absorption reducer and water-repellent

product to prevent rising moisture at least two or three days before grouting.

In all cases, above all for outdoor paving, water-based water-repellents are

preferable to solvent-based ones.

In fact, the former can be applied even if the flooring or paving is not perfectly

dry. It is advisable to apply the product with a low-pressure (airless) spray for

more even coverage.

The various excellent products on sale include:

“IPA 16” by Geal

“KEMIOSIL 116” by New Chemical

“HP/98” by Fila

Page 41: Pica Cotto Floor Tiles Manual

Laying The Tiles: Sealing The Joints

Pre–waterproofing / The advantages

NO FORMATION

OF

EFFLORESCENCE

OR “DARK MARKS

QUICK AND

EASY WASHING

REDUCTION IN

WAITING TIMES

FOR FINISHING

REDUCTION IN

OVERALL

TREATMENT

COSTS

EASIER

FINISHING

Page 42: Pica Cotto Floor Tiles Manual

Laying The Tiles: SYNOPTIC CHART

COTTO RUSTICO COTTO PRATICO/

PROTETTO

LINEA

CASATO

COTTO

PRONTO

OUTDOOR

PAVINGS

AND DECOR

COTTO

FATTO A MANO

(HANDMADE

COTTO)

INTENDED USE Indoors Outdoors Indoors Outdoors Indoors Indoors Outdoors Outdoors Indoors Outdoors

(Rustic-

ated)

RECOMMEN-

DED

INSTALLATION

METHOD

Mortar / Adhesive Mortar / Adhesive Adhesive Mortar / Adhesive Semi-dry

Mortar

Adhesive

Mortar / Adhesive

TYPE OF

ADHESIVEKerabond Kerabond

+ Isolastic

/Keraflex

Kerafloor Kerafloor

+Isolastic

/ Keraflex

Kerabond Kerafloor Kerafloor

+Isolastic

/ Keraflex

Keraflex Kerafloor Kerafloor

+

Isolastic

OPTIMUM

GROUT WIDTH

DIMENSIONS

5mm 5mm 5mm 5mm Touching

4mm (Bis)

6mm Rusticated

3mm Smoothed

TYPE OF SEAL Grout

Keracolor Grosso

Grout

Keracolor Grosso/Fine

Grout

Keracolor

Grosso

Grout

Keracolor Grosso/Fine

Grout

Keracolor

Grosso/Fine

Grout

Keracolor Grosso

23 – 50 – 10 - 3 – 7 23 – 50 – 10 – 3 – 7 23 – 50 - 3 23 – 50 – 10 – 3 – 7 23 – 50 – 10 23 – 50 – 3

PRE-WATER-

PROOFINGRecommended for

colour 10

NO NO NO Necessary for

colour 10

Recommended

for grout and

50

Always necessary

23_ MANHATTAN / 50_ TITANIUM / 10_ CEMENT / 3_ BAHAMABEIGE / 7_ BROWN

Page 43: Pica Cotto Floor Tiles Manual

Treatment

Page 44: Pica Cotto Floor Tiles Manual

Treatment:

Technical times

COTTO

RUSTICO

COTTO

PRATICO/

PROTETTO

LINEA

CASATO

COTTO

PRONTO

OUTDOOR

PAVINGS AND

DECOR

COTTO

FATTO A MANO

(HANDMADE

COTTO)

LAYING

METHOD

CLIMATE CLIMATE CLIMATE CLIMATE CLIMATE CLIMATE

Warm

Dry

Cold

Damp

Warm

Dry

Cold

Damp

Warm

Dry

Cold

Damp

Warm

Dry

Cold

Damp

Warm

Dry

Cold

Damp

Warm

Dry

Cold

Damp

MORTAR

(Days)

20 - 25 30 - 40 5 - 7 8 - 10 Not foreseen 5 - 7 8 - 10 20 - 25 30 - 40 30 - 40 45 - 60

ADHESIVE

(Days)

3 - 5 5 - 7 2 - 3 3 - 5 2 - 3 3 - 5 2 - 3 3 - 5 3 - 5 5 - 7 5 - 7 10 - 15

Cleaning

The time required to wait between installation and treatment is given by:

Curing or the release of salts from the terracotta tile

The stabilising time of the laying bed and grout width

Tile surface drying

Before washing, it is recommended to respect the times provided in this table:

NOTE: The times given in the table are purely indicative.

For subgrades in expanded clay with damp proofing, the waiting times for mortar should be doubled and the area heated where possible.

Page 45: Pica Cotto Floor Tiles Manual

Treatment:

Technical findings _ Surface moisture

Cleaning

The surface of the cotto to be washed must have a relatively low degree of

surface moisture, less than 25%; in any case, grout widths will always have a

higher degree of moisture (up to 30-35%).

In fact, it is more difficult to clean the surface impurities and oxidation normally

present from an excessively damp tile than from a relatively dry one.

However, it is more important to keep this factor under control between washing

and finishing. It is extremely risky to finish tiles and grout widths where there is

a high degree of surface moisture.

This “pock-marked effect” problem may even occur a few

months after handover, especially when the finishing

treatment has been carried out using varnishing or film-

forming products, which should be avoided in any case.

This reduces or prevents the residual moisture present in

the substrate from being released through the tile.

Page 46: Pica Cotto Floor Tiles Manual

Treatment:

Technical findings _ Joint configuration and colour

Cleaning

Often, one of the determining factors in achieving an excellent overall finished

appearance of treated surfaces in cotto is the way in which the joints are

treated.

At times, excellent treatment of the terracotta tiles shows up an awful

appearance in treated joints.

To obtain an even-coloured joint, it is advisable to proceed as follows:

If the joint is very grainy and absorbent, after washing with buffered acid, finish

with unpigmented and/or low-penetration treatment products (wax-resin water

emulsions)

If the joint already varies in colour, due to unevenly mixed

grout, different cement batches, or to the replacement of tiles

considered to be faulty, a medium- or dark-coloured finishing

treatment followed by colouring the joints with pigments is

recommended.

Example of mismatched joint colours following resumed work or tile replacements.

Page 47: Pica Cotto Floor Tiles Manual

Treatment:

Washing

Cleaning

Preliminary cleaning is aimed at:

Removing unwanted substances and restoring the original colour and

appearance

Freeing the characteristic porosity so that the final protective treatment

can be absorbed deep down.

Knowledge of the origins of terracotta (formats, surface finish, installation) also

offers useful information with regard to arranging the work to be performed with

the following operational means:

CHEMICAL PRODUCTS and MECHANICAL EQUIPMENT

Page 48: Pica Cotto Floor Tiles Manual

Treatment:

Washing _ Chemical products

Cleaning

When talking about cleaning cotto, the first and only thing that comes to mind is an

acid wash and in most cases, muriatic acid.

However, it is not always necessary just to remove the surface lime scale deposits,

it is also necessary to remove many other substances used on site or which have

deposited on the material over time (cotto used out of doors), or even products

purposefully applied to the surface itself (incorrect treatments).

This requires:

Dedicated action

which is performed according to the choice of chemical products with specific

dissolving action for the prevalent type of dirt present.

Fast action

It is necessary for the dirt residues to be easily and completely removed from the

cotto surface in the least amount of time possible and using the least amount of

water.

This factor, which is known as “emulsifying the dirt” is of fundamental importance

to successful washing.

Page 49: Pica Cotto Floor Tiles Manual

Treatment:

Washing _ Chemical products

Cleaning

REACTIVE

DETERGENTS

TRADITIONAL

REACTIVE AGENTSNEW COTTO

INCORRECTLY

TREATED COTTO

SCALE REMOVER

LIME REMOVER

PICKLING AGENT

(water solution)

MURIATIC ACID

HYDROCHLORIC ACID

(water solution)

Cement grout and lime

scale residues; Colour

wash paint; Saline

efflorescence

Neutralises after alkaline

wash;

Emulsifies after solvent

wash;

Cleans away lime scale

soiling

STRONG DEGREASER

ALKALINE WAX REMOVER

(water solution)

CAUSTIC SODA

SODIUM HYDROXIDE

(water solution)

Dark oxidation;

Pollution stains;

Mould and algae

Dissolves natural and

fatty wax treatments

FILM REMOVER

PAINT REMOVER

STRONG WAX REMOVER

(solvent solution)

SPIRIT

NITRE THINNER

(solvent solution)

Removes synthetic

stains;

Quarzites and synthetic

paints

Wax remover that

dissolves synthetic and

polymer treatments;

Dissolves metalized

acrylics in resins,

varnishes and silicones

Traditional reactive agents, although they have a strong breakdown action on the

substances present, lead to notable re-absorption of the broken down dirt,

especially during the rinsing process, which requires copious amounts of water.

Page 50: Pica Cotto Floor Tiles Manual

Treatment:

Washing _ Chemical products

Cleaning

During cleaning and due to the surface acting agents it contains, a good reactive

detergent maintains the broken down particles in suspension and this allows them

to be quickly and completely removed with a minimum amount of water during the

rinsing stage.

COTTO MUST BE CLEANED QUICKLY, WELL, AND USING THE SMALLEST POSSIBLE

AMOUNTS OF WATER AND REACTIVE SUBSTANCES, ESPECIALLY WHEN USING

TRADITIONAL REACTIVE PRODUCTS.

DETERDEK and FILADRASTIC ,

respectively de-scaler and lime remover;

strong degreaser and alkaline wax remover.

Page 51: Pica Cotto Floor Tiles Manual

Treatment:

Washing _ Chemical products

Cleaning

REACTIVE

DETERGENTSLIST PRODUCTS FILA PRODUCTS GEAL PRODUCTS

DE-SCALER

LIME REMOVER

PICKLING AGENT

(water solution)

ACIDO TAMPONATODETERDEK

FILA PH ZERO

SERVICE ACIDO

ACIDO 13H3 FORTE

ESTRATTORE ACIDO

FORTE

STRONG DEGREASER

ALKALINE WAX REMOVER

(water solution)

ALCALE FILADRASTIC

SERVICE ALCALE

CB – 90

ESTRATTORE ALCALE

FORTE

FILM REMOVER

PAINT REMOVER

STRONG WAX REMOVER

(solvent solution)

/FILASOLV

SERVICE SOLVENTE

ESTRATTORE SOLVENTE

FORTE

Correspondence between list products and the brand names of some companies.

Page 52: Pica Cotto Floor Tiles Manual

Treatment:

Washing _ Mechanical equipment

Cleaning

Single-brush polisher

Liquid vacuum cleaner

Synthetic pads and discs with

different abrasive levels.

Page 53: Pica Cotto Floor Tiles Manual

Treatment:

Washing _ New cotto

Cleaning

CHEMICAL PRODUCTS: see previous tables.

EQUIPMENT: single-brush floor polisher (*) with hard

abrasive disc for washing (darker colours), liquid vacuum

cleaner and wiper.

HOW TO PROCEED: work on dry flooring. Pour the detergent directly onto the

surface and spread it with the wiper. Unless otherwise indicated, it is always best to

start out using an undiluted product. Brush it thoroughly with the floor polisher at

medium-low speed and a weight pressure of no less than 30 kg. Quickly vacuum up

the liquid because cotto tends to absorb washing residues and the reactive products

used deep down. For this reason, it is best to work in pairs: one to operate the floor

polisher and the other the liquid vacuum cleaner. A final rinse with clean water is

most important to eliminate any last residues of dirt or washing products; this must be

performed quickly and using the floor polisher or a broomcorn brush. After rinsing,

vacuum up the remaining liquid and thoroughly dry the surface with cloths and

sponges.

(*) Caution! For terracotta tiles from the Casato line, use broomcorn brushes or soft pads only, and dilute the

detergent so that the concentration is less aggressive.

Page 54: Pica Cotto Floor Tiles Manual

Treatment:

Washing _ Natural actions and treatments requiring correction

Cleaning

CHEMICAL PRODUCTS: correction assumes knowledge of the products used for the

prior intervention. The choice of detergent product is extremely easy.

EQUIPMENT: single-brush polisher with hard abrasive disc for washing (darker

colours), liquid vacuum cleaner and wiper.

HOW TO PROCEED: similarly to that described in the previous section. It is

advisable to make a preliminary test on a more deteriorated area of the surface.

1 2 3

1 – cleaning oxidation marks; 2 – cleaning mould and algae; 3 – cleaning an incorrect treatment

Page 55: Pica Cotto Floor Tiles Manual

Treatment: Protection

Primers

The protection stage requires the application of primers.

According to their action, primers are divided as follows:

WATER REPELLENTS (deep down protection)

OIL REPELLENTS (surface protection)

OIL AND WATER REPELLENTS (combined protection, deep down/surface)

TRADITIONAL OIL PRIMERS (combined protection, deep down/surface)

With reference to the solution in which they are dispersed:

SOLVENT BASED

WATER BASED

Page 56: Pica Cotto Floor Tiles Manual

Treatment: Protection

Primers

Solvent-based primers are characterised by rather small molecules and a high

degree of chemical inertia; for this reason they operate deep down.

They are excellent from a performance viewpoint, although they should only be

used in “expert hands”. They also dry quickly and must only be applied to

perfectly dry flooring or paving.

Water-based primers on the other hand, are characterised by a slower drying

process and by rather large molecules (water). For this reason, they are

recommended for waterproofing highly absorbent flooring.

They are also easier to apply, since they can also be used on material that is still

damp.

These primers have less of an adverse effect on the environment although they do

lose their effectiveness as time passes.

Page 57: Pica Cotto Floor Tiles Manual

Treatment: Protection

Technical times

COTTO RUSTICO COTTO PRATICO/

PROTETTO

LINEA

CASATO

COTTO

PRONTO

OUTDOOR

PAVINGS AND

DECOR

COTTO

FATTO A MANO

(HANDMADE

COTTO)

PROTECTION PROTECTION PROTECTION PROTECTION PROTECTION PROTECTION

Solvent

based

Water

based

Solvent

based

Water

based

Solvent

based

Water

based

Solvent

based

Water

based

Solvent

based

Water

based

Solvent

based

Water

based

7-15

days

4 hours 3- 4

days

/ Not foreseen Not foreseen (*) 7-15

days

4 hours 15-20

days

4 hours

(*) Unless a certain stain-proof action is required. In this case, it is possible to apply a solvent-based oil- and

water-repellent product.

This table contains the minimum times required to wait between the completion of

washing operations and the protection stage:

Page 58: Pica Cotto Floor Tiles Manual

Treatment: Protection

Water repellents

Siloxane primers with a high degree of penetration, chemical inertia, and lasting action.

They prevent rising moisture and water absorption. They also combat the formation of

efflorescence, “dark marks”, and mould.

They leave the transpiration capacity (vapour permeability) of the material unchanged.

Especially indicated as initial primers for treating tiles laid indoors and out. They also

favour the even absorption of subsequent treatment products: wax for interiors and oil

repellents for exteriors.

EVAPORATED WATER (drying)

CHEMICAL BARRIER

RISING MOISTURE

terracotta surface

Vapour

passage area

INVISIBLE HYDROPHOBIC (dry) AREA

EVAPORATION INTERFACE

Page 59: Pica Cotto Floor Tiles Manual

Treatment: Protection

Oil repellents

These give the material a fluoride-based, stainproof, protective surface that is

completely invisible. They do not alter the original colour of the material. They do not

film and they also do not change the vapour permeability (transpiration) of the original

material.

They are not able to receive subsequent treatment products but can be applied on top

of water repellents. Their use is practically limited to outdoor paving only.

STAINING SUBSTANCES

WATER SOLUBLE GREASE

terracotta surface

CHEMICAL BARRIER

INVISIBLE

STAINPROOF

PROTECTION

Page 60: Pica Cotto Floor Tiles Manual

Treatment: Protection

Oil and water repellents

These are normal mixes, in solvents, of fluoridated copolymers with a stainproofing

action and siloxane primers with a deep-down water-repellent action to provide dual

oil- and water-repellent protection.

They do not create films, or substantially alter the transpiration capacities of the

material. They add a slight colour tone to the original shade.

They are moderately receptive to subsequent treatment products such as, for example,

neutral liquid wax in the case of indoor flooring.

STAINING SUBSTANCES

WATER SOLUBLE GREASE

terracotta surface

CHEMICAL BARRIER

STAINPROOF PROTECTION

WATER-REPELLENT PROTECTION

RISING MOISTURE

Page 61: Pica Cotto Floor Tiles Manual

Treatment: Protection

Traditional oil primers

Primers with vegetable oil or natural wax bases and resins in plant-based

solvents for water-repellent and stainproof protection. Compared to the

traditional oil-based mixes, (linseed oil), they penetrate and dry with greater

ease. They add a more or less intense colour tone.

Suitable for use on flooring or paving where there is no risk of rising

moisture, indoors or in covered outdoor areas.

STAINING SUBSTANCES

POROSITY

SATURATION AREA

PHYSICAL BARRIERWATER SOLUBLE “GREASE”

terracotta surface

Page 62: Pica Cotto Floor Tiles Manual

Treatment: Protection

Protection _ Chemical products

ES / 82 and OP / K ,

Respectively, deep-down water repellent and oil

and water repellent. Both are solvent based.

Page 63: Pica Cotto Floor Tiles Manual

Treatment: Protection

Protection _ Chemical products

ACTION SOLUTION LIST PRODUCTS FILA PRODUCTS GEAL PRODUCTS

WATER REPELLENT

In water / HP / 98 IPA - 16

In solvent IDROREPELLENTE ES / 82 ICR - 17

WATER AND OIL

REPELLENT

In water/

FILASPRINT 2000 /

In solvent ANTIMACCHIA OP / KBARRIER 2

LI-COT / LI-COT NEREO

OIL REPELLENTIn water

/W / 68 /

In solvent/

/ BASOIL

Correspondence between list products and the brand names of some companies.

Page 64: Pica Cotto Floor Tiles Manual

Treatment: Finishing And Maintenance

Since terracotta tiles are made from a rough material that is highly absorbent

compared to other traditional tile types, it is necessary to clean and protect them

and also to give them a tone and performance that leave them easy to care for

using modern means in the areas in which they are installed.

Finishing operations for flooring laid indoors normally take the form of applying:

SOLVENT-BASED OIL-WAX DISPERSIONS ( Wax paste)

WATER-BASED RESIN-WAX EMULSIONS ( Liquid wax )

Wax pastes (traditional treatment) “nourish” the tiles deep down, giving them a

“warm” appearance. They are available in different colours:

natural (neutral), blond (yellow), leather (brown), and aged (antique brown).

In this way, it is possible to give tone to the tiles to obtain specific colour effects.

Just applying neutral wax paste creates a slight colour effect without altering the

original shade of the flooring.

Page 65: Pica Cotto Floor Tiles Manual

Treatment: Finishing And Maintenance

Wax paste is not diluted and it is applied after the base coat of water repellent.

It must be applied in two layers at a distance of 8 hours from one another to obtain

a more even result and to be able to correct the tone of the first application, if

necessary.

It is advisable to apply the wax with a normal synthetic bath sponge and to buff it

later with a woollen cloth or floor polisher.

Darker colours should always be applied as a second coat.

Variations in the finished appearance of original cotto, created by different finishing

treatments.

Page 66: Pica Cotto Floor Tiles Manual

Treatment: Finishing And Maintenance

Liquid waxes are used to provide a final finishing coat.

They give the flooring:

Wearproof surface protection

Light stainproof protection

A base for subsequent maintenance

These are normally emulsions of high-quality natural wax with added polymers. It

is also possible to buy formulas that create a more wear-resistant protective layer

(synthesis waxes), which are therefore more suitable to areas subject to a great

deal of traffic (offices, restaurants, etc.).

Cotto Wax

Neutral liquid wax for terracotta

As a final finishing coat, this product is applied

over the wax paste with a cloth, mop or other

wax application means.

If the flooring is finished with liquid wax only, it is

advisable to apply it with a wide brush.

Page 67: Pica Cotto Floor Tiles Manual

Treatment: Finishing And Maintenance

Maintenance

Maintenance is performed more or less frequently according to the

condition of the flooring and to different personal requirements.

For routine maintenance, it is sufficient to wash the flooring with a diluted

solution of liquid wax (2–3 glasses in a bucket of water); for extraordinary

maintenance, re-apply a coat of pure wax, using a brush.

Every so often, use a mild de-greasing detergent to remove any black

marks from the flooring and to prevent layers of wax from building up.

FilaCleaner and liquid wax for cotto floor maintenance.

Page 68: Pica Cotto Floor Tiles Manual

Treatment: Finishing And Maintenance

Finishing and maintenance - Products

TYPE LIST PRODUCTS FILA PRODUCTS GEAL PRODUCTS

WAX PASTE /

CERA IN PASTA

(Neutral, Yellow, Brown,

Antique Brown)

DRESS

(Neutral, Dark Brown,

Rustic)

LIQUID WAXCERA LIQUIDA

NEUTRA

COTTOWAX

Klinwax

WOP

(Matt / Polished)

DESCALING

DETERGENT DETERGENTE FILACLEANER CB - 90

Correspondence between list products and the brand names of some companies.

Page 69: Pica Cotto Floor Tiles Manual

Treatment: Treatment Diagrams

COTTO

RUSTICO

COTTO

PRATICO/

PROTETTO

LINEA

CASATO

COTTO

PRONTO

OUTDOOR

PAVINGS AND

DECOR

COTTO

FATTO A MANO

(HANDMADE

COTTO)

AREA AREA AREA AREA AREA AREA

Indoor Outdoor Indoor Outdoor Indoor Indoor Outdoor Outdoor Indoor Outdoor

FINISHING

DIAGRAM

(Type)A - B C D E F G H I L M

Page 70: Pica Cotto Floor Tiles Manual

Treatment:

Indoor treatment diagram _ Traditional Cotto Rustico

Acido Tamponato

(buffered acid)

Idrorepellente

(water repellent)

Cera Liquida Neutra

(neutral liquid wax)

Wax Paste

Wax Paste

Cera Liquida Neutra Polymer Wax Emulsion

or

or

7-15 days min.

24 hours 4 hours

8 hours

8 hours

7-15 days min.

8 hours

A

Page 71: Pica Cotto Floor Tiles Manual

Treatment:

Acido Tamponato

(buffered acid)

Idrorepellente

(water repellent)

Cera Liquida Neutra

(neutral liquid wax)

Cera Liquida Neutra

Cera Liquida Neutra Polymer Wax Emulsionor

24 hours

8 hours

8 hours

7-15 days min.

8 hours

Indoor treatment diagram _ Traditional Cotto Rustico

B

Page 72: Pica Cotto Floor Tiles Manual

Treatment:

Outdoor treatment diagram _ Traditional Cotto Rustico

C

Acido Tamponato

(buffered acid)

Idrorepellente

(water repellent)

Antimacchia

(stainproof product)or

7-15 days min.

For water-repellent treatments For water and oil-repellent treatments

STOP

WITH CAUTION

Page 73: Pica Cotto Floor Tiles Manual

Treatment:

Acido Tamponato

(buffered acid)

Cera Liquida Neutra

(neutral liquid wax)

Idrorepellente

(water repellent)or

8 hours2 hours

Wax Paste or

Cera Liquida Neutra Cera Liquida Neutra

Cera Liquida Neutra

2 days 2 days 3 – 4 days

24 hours

2 hours

Indoor treatment diagram _ Cotto Pratico / Protetto

D

Page 74: Pica Cotto Floor Tiles Manual

Treatment:

Acido Tamponato

(buffered acid)

Antimacchia

(stainproof product)

Antimacchia

from 3-4 months

to 1-2 years

2 – 4 days min.

Outdoor treatment diagram _ Cotto Pratico / Protetto

E

Page 75: Pica Cotto Floor Tiles Manual

Treatment:

Acido Tamponato

(buffered acid)

Wax supplied

2 days

Indoor treatment diagram _ Cotto Linea Casato

F

Caution!

DILUTE

APPLY WITH

A CLOTH

APPLY WITH

A CLOTH

Page 76: Pica Cotto Floor Tiles Manual

Treatment:

Indoor treatment diagram _ Cotto ProntoZoni

G

Acido Tamponato

(buffered acid)

Cera Liquida Neutra

(neutral liquid wax)

Antimacchia

(stainproof product)or

2 days 3 - 4 days

For a secure stainproofing action

APPLY WITH

A CLOTH

Page 77: Pica Cotto Floor Tiles Manual

Treatment:

Outdoor treatment diagram _ Cotto ProntoZoni

H

Acido Tamponato

(buffered acid)

Antimacchia

(stainproof product)

3 - 4 days

For a secure stainproofing action

STOP

Page 78: Pica Cotto Floor Tiles Manual

Treatment:

Treatment diagram for the Outdoor Pavings and Decor Line

I

Warning!

Only if given prior waterproofing

treatment. Alternatively, 7-15 days

Acido Tamponato

(buffered acid)

Water-based water repellent

4 hours

Sealing the joints

Water-based water repellent

Antimacchia

(stainproof product)or

2 – 4 days min.

STOP

WITH CAUTION

Page 79: Pica Cotto Floor Tiles Manual

Treatment:

Indoor treatment diagram _ Smooth Cotto Fatto a Mano / Crete

L

Acido Tamponato

(buffered acid)

Water-based water repellent

4 hours

Sealing the joints

Water-based water repellent

Idrorepellente

(water repellent)or

2 – 4 days min.

Wax paste

Polymer wax emulsion

Cera Liquida NeutraCera Liquida Neutra

(neutral liquid wax)

Cera Liquida Neutra

or or

24 hours

8 hours

24 hours

8 hours

8 hours8 hours

8 hours

Cera Liquida Neutra

Warning!

Only if given prior waterproofing

treatment. Alternatively, 20 days.

Page 80: Pica Cotto Floor Tiles Manual

Treatment:

Outdoor treatment diagram _ Rusticated Cotto Fatto a Mano

I Borghi and Vicoli

Acido Tamponato

(buffered acid)

Water-based water repellent

4 hours

Sealing the joints

Water-based water repellent

Idrorepellente

(water repellent)or

2 – 4 days min.

M

Warning!

Only if given prior waterproofing

treatment. Alternatively, 20 days.

Page 81: Pica Cotto Floor Tiles Manual

Troubleshooting:

Floors that have not yet been treated

Black marks on the floor

These occur in the form of dark marks in various shapes. They are most

probably caused by oxidation. An alkaline product is required (Service alcale Geal /

Filadrastic). Wash thoroughly and then repeat the operation, this time using

buffered acid (Service acido Geal / Deterdek Fila) to neutralise the alkaline solution.

Grout residues

Clean with buffered acid (Service acido Geal / Deterdek Fila). More stubborn build up

can be removed with specific products used in higher concentrations (Acido 13H3

forte Geal / Fila PH Zero).

Saline efflorescence

This appears if the washing operation was performed too early or inaccurately.

Wash the tiles again, not forgetting to respect the technical times. From laying

to acid wash: 40 days for traditional mortar laying; 15 days for adhesive laying;

2-3 months for handmade cotto laid using mortar.

(see table on slide 42)

Page 82: Pica Cotto Floor Tiles Manual

Floors with finishing treatment

Drips of cold oil

Use kitchen paper and wash with a mild degreasing detergent (CB-90 Geal / Fila

Cleaner), such as used for normal maintenance. If cleaning is performed quickly

enough, there will be no remaining marks. If this is not the case, use a strong

film and wax remover (Service idrosolv Geal / Fila DX/83), neat and directly on the

stained tile, which must then be carefully rinsed. When the tile is dry, apply a

coat of neutral liquid wax (Wop Geal / Cottowax Fila) or the same product used in

the final coat of floor treatment.

Black heel marks

Or marks from the caps on chairs or furniture. Use a mild degreasing detergent

(CB-90 Geal / Fila Cleaner) neat, applying it with a damp abrasive sponge. Rub in,

rinse and then apply neutral liquid wax (Wop Geal / Cottowax Fila).

White heel marks

This probably means that there is too much wax on the tiles and therefore, it is

best not to use any more for a while. Wash the floor with a mild degreasing

detergent (CB-90 Geal / Fila Cleaner) such as used for normal maintenance and use

a floor polisher on a regular basis.

Troubleshooting:

Page 83: Pica Cotto Floor Tiles Manual

Treated floors

Layers of built up wax or stubborn dirt

Wash the floor with a strong film and wax remover (Service idrosolv Geal / Fila

DX/83) and rinse. Apply a coat of neutral liquid wax (Wop Geal / Cottowax Fila).

The flooring under a pot has become lighter

This is probably due to lime scale residues caused by water. It is sufficient to

wash the affected area with a buffered acid (Service acido Geal / Deterdek Fila) and

then, if necessary, to apply neutral liquid wax (Wop Geal / Cottowax Fila). If the

problem is caused by dampness, which is particularly high underneath a plant,

use a solvent-based wax remover (Service solvente Geal / Filasolv), scrubbing with

an abrasive sponge and cleaning up any residues with kitchen paper or dry

cloths. Then apply a coat of wax paste for cotto (Dress Geal / Cera in pasta Fila) and

finish off with a coat of neutral liquid wax (Wop Geal / Cottowax Fila).

Troubleshooting:

Page 84: Pica Cotto Floor Tiles Manual

Tiles laid outdoors

Blackened paving

Rain, dust and smog can blacken cotto tiles laid outdoors. It is sufficient to

wash the paving with a strong degreasing detergent (Service idrosolv Geal / Fila

DX/83) to remove the dirt that has accumulated over time.

Tyre marks

Wash thoroughly with a strong degreasing detergent (Service idrosolv Geal / Fila

DX/83), and a stiff brush. Rinse.

Moss and mould

Wash with an alkaline product (Service alcale Geal / Filadrastic) and a hard brush.

Then apply buffered acid (Service acido Geal / Deterdek Fila) and rinse. To prevent

this problem, apply two coats of water repellent (ICR 17 Geal / Fila ES/82) to clean,

dry paving.

Troubleshooting:

Page 85: Pica Cotto Floor Tiles Manual

Specific Notes About Our Flooring And Paving:

Cotto Pratico / Protetto

Traditional cotto Cotto Pratico / Protetto

•Waterproofed by immersion

•Wide range of floor and special pieces

•Releases no efflorescence

•Does not form mould

•Easier to clean

•Ideal for indoor and outdoor use

Page 86: Pica Cotto Floor Tiles Manual

Specific Notes About Our Flooring And Paving:

Cotto Pratico / Protetto

In the interests of correct information, it is best to specify:

Indoor flooring: the product requires a wax finish

Outdoor paving: do not apply any type of finish,

although a stainproofing product can be applied to areas

at risk from staining.

Warning!Do not consider this cotto to be a pre-treated or ready-to-use

product, or even a non-absorbent or stainproof cotto

Cotto Pratico has extremely fast

installation and finishing times…

Page 87: Pica Cotto Floor Tiles Manual

Specific Notes About Our Flooring And Paving:

Cotto Linea Casato

•Waxed in a controlled environment

•Available in 3 colours

•Does not release efflorescence

•Easy to clean

•Immediate finish

This is given a “hot wax” treatment in a controlled

environment: the result is a surface with improved strength,

durability and more even colour tones.

This can easily be defined as a pre-treated cotto

Page 88: Pica Cotto Floor Tiles Manual

Specific Notes About Our Flooring And Paving:

In the interests of correct information, it is best to specify:

This is a cotto for indoor use only

It may only be laid using adhesives

Warning!Do not define this cotto as being a stainproof product;

avoid soiling it excessively during grouting operations…

Washing operations must be performed “delicately” !

Cotto Linea Casato

It must be finished using the relevant special wax

Page 89: Pica Cotto Floor Tiles Manual

Specific Notes About Our Flooring And Paving:

Cotto ProntoZoni

Our Research and Development laboratory has devised a

mix of fluxes, that is applied to the product while still

“dry”.

After firing, the product is waterproofed by being

immersed in a water-based water-repellent.

Page 90: Pica Cotto Floor Tiles Manual

Specific Notes About Our Flooring And Paving:

Cotto ProntoZoni

This maintains all of the beautiful qualities of real cotto

flooring, but without any of the characteristics that have

classified it as “difficult”.It needs no treatment – not now or ever…

Resistant to wear, chemical agents and the elements.

The presence of corundum gives the product its high

degree of surface strength.

The characteristics of this mix mean that the product can

absorb and release water, but not liquids of higher

density.

Page 91: Pica Cotto Floor Tiles Manual

The contents of this presentation

have been optimised and revised by the Technical Division of

Industriepica in collaboration with:

Geal srl _ Agliana (PT)

Fila Industria chimica spa _ S. Martino di Lupari (PD)

Mapei spa _ Milan

Tenax spa _ Italy

Sources:

“Le piastrelle di ceramica” by

A.Tenaglia, G. Timellini, C. Palmonari

In-house publication from Centro Ceramico – Bologna

“Il cotto toscano” un’antica piastrella ancora

da apprezzare pienamente by E. Giusti

Geal srl _ Agliana (PT)

All rights reserved. Reproduction, in any form,

of written or illustrated parts of this booklet

is strictly prohibited, unless expressly authorised.