What are the installation process and construction difficulties of terrazzo prefabricated panels?

Analysis of Installation Process and Construction Difficulties of Terrazzo Prefabricated Panels
1, Core installation process flow
1. Grassroots treatment and defense line positioning

Grassroots treatment: Thoroughly remove floating soil, oil stains, slurry and other debris on the surface of the base layer, level the uneven parts with cement mortar, and ensure that the flatness error of the base layer does not exceed 4mm (within 2m span). If the base layer is made of concrete, it needs to be cured for more than 4 weeks, with a moisture content controlled within 5%, a shear strength of ≥ 0.5MPa, and a tensile strength of ≥ 1.0MPa.
Defense line positioning: According to the design drawings, draw the ground elevation from the wall+50cm line, and mark the cross control line and grid line. When laying on a large area, it is necessary to set up reinforcement bars to control the slope and flatness; When there are patterns or different colored panels, it is necessary to draw a detailed construction drawing to avoid wandering and gaps.

2. Material preparation and trial laying

Material screening: Check the specifications, color, and texture of prefabricated panels, remove defective panels such as cracks, missing corners, and missing edges, number them according to design requirements, and pre arrange them to ensure consistent panel size and uniform color within the same room.
Trial laying adjustment: Trial laying of slabs on the leveling layer, checking the thickness and flatness of the mortar, adjusting the arrangement order of the slabs to avoid narrow strips or asymmetrical situations. After the trial laying is qualified, it will be numbered for sequential operation during formal laying.
3. Key steps of paving construction

Thin bottom laying method:
Base layer coating: Apply adhesive with a toothed trowel to form 6-8mm thick serrated stripes, ensuring no interruption.
Back coating of board: Clean the floating dust on the back of the board, apply 3-4mm thick adhesive, supplement adhesive on all four sides and chamfer.
Laying and kneading: Use suction cups to place the board steadily, fully knead and press it, and use a rubber hammer to strike from the center to the surrounding areas. After leveling, check whether the edges and corners are dense (violent tapping is strictly prohibited).
Semi dry wet laying:
Leveling layer construction: Lay a 1:3 dry hard cement mortar with a thickness of 2.5-3.0cm, and use an iron trowel to compact and level it.
Combination layer treatment: Brush a plain cement slurry with a water cement ratio of 0.5 on the leveling layer. When laying, all four corners should fall down at the same time, and lightly tap with a rubber hammer until it is compacted.
4. Seam retention and sealing treatment

Requirements for joint retention: 1-2mm joints should be left between the plates, and 6-10mm structural expansion joints should be reserved every 8-10m in both vertical and horizontal directions, deep to the base layer, to prevent stress from causing bulging or cracking.
Jointing process: After 24 hours of laying, use cement mortar to fill the joint to 2/3 of the height, and fill the remaining 1/3 with the same color cement slurry and wipe it tightly. Clean the excess mortar on the surface.
5. Maintenance and finished product protection

Maintenance period: After the paving is completed, cover with wet sawdust or plastic film for 3 days of maintenance, and prohibit people from entering; After 3 days, lay a soft carpet and protect it with plywood for 7-10 days.
Finished product protection: Close the room or set up fences to avoid collision with door frames, walls, and pipelines; It is strictly prohibited to mix mortar or pile up debris on the surface layer.
2, Construction difficulties and solutions
1. Inadequate grassroots treatment leads to hollowing out

Difficulty: The base layer of floating slurry is not cleaned, the moisture is insufficient, or the moisture content is too high, which affects the bonding strength.
Solution:
Thoroughly remove the base layer coating, rinse with a high-pressure water gun, and air dry;
Water the area one day before laying, but there should be no standing water;
The concrete base needs to be cured for more than 4 weeks with a moisture content of ≤ 5%.
2. The height difference between sections exceeds the standard

Difficulties: Plate thickness errors, poor leveling of the base layer, or improper paving operations resulting in a 2-3mm height difference.
Solution:
Strictly screen the sections and eliminate those with excessive thickness deviation;
Use a laser level to check the flatness of the base layer, and re level if the error exceeds the standard;
When laying, use a level ruler to calibrate at any time, and re lay where the height difference is too large.

3. Hollowing and cracking issues

Difficulties: Improper adhesive ratio, premature stress after laying, or stress cracking caused by changes in environmental temperature and humidity.
Solution:
Select high elasticity waterproof adhesive (such as Hanshi 929 non hollow elastic adhesive) to form an elastic adhesive layer that absorbs deformation stress;
No one is allowed to enter within 3 days after laying, and during the maintenance period, avoid exposure to direct sunlight or sudden cold and heat;
Reserve expansion joints when laying on a large area and carry out staggered construction.
4. Difficulties in controlling aesthetics

Difficulty: Incomplete exposure of grid strips, uneven distribution of aggregates, or significant abrasion affecting the appearance.
Solution:
Control the height of the mortar when pasting the dividing strip to ensure that the stones are clearly exposed after polishing;
Reduce walking when spreading terrazzo slurry to avoid sinking of aggregates;
For the third round of fine grinding, use ultra-fine grinding stones to eliminate grinding marks.

5. Construction challenges in complex environments

Difficulty: Wet environments (such as basements) or high temperature environments (such as sunrooms) affect the bonding effect.
Solution:
Wet environment: Apply waterproof interface agent on the base layer and use fast setting adhesive;
High temperature environment: After laying, cover with a damp cloth and cure for 24 hours to avoid rapid evaporation of moisture.