Large modular tile is growing faster than ever in popularity, as it is prized for its elegant aesthetic and clean, open look in both commercial and residential settings. Stone, ceramic and porcelain tile in sizes of 16 x 16, 18 x 18 and even 24 x 24 inches is increasingly common, and can help create the illusion of a larger space. But as every tile installation professional knows, setting tile that is greater than 12 x 12 inches can be time-consuming and physically grueling, and comes with some serious challenges. Thanks to new advances in mortar technology, leading manufacturers are creating products that solve these problems and ease the physical demands for tile professionals working with larger tile.
First, they must back-butter the tile with mortar, an extra step that is necessary to ensure complete mortar coverage on the back of the tile and proper bonding to the substrate. Second, when setting the tile in the mortar bed, a tremendous amount of pressure (“beating inâ€) is required to smooth out the ridges and create a good bond. The average maximum pressure that an installer is able to apply to a tile is about 30 pounds. While this is adequate for tile up to about 12 inches, it will require nearly two and a half times this force to set an 18- x 18-inch tile. If the pressure is insufficient, the ridges do not smooth together, and coverage is not adequate, leaving air pockets under the tiles. They will sound hollow and are at risk for popping up.