APEX FITOUTS

Method Statement • Flooring & Stone Works

Natural Marble Slab & Pattern Flooring (6-Sided Pre-Sealing & 15-Stage Diamond Polishing)

Doc ID MS-FLR-005

Rev / Ver R0 / 2026.1

Project / Package [Insert Project / Package]

Client / PMC / Architect [Insert Client / PMC / Design Consultant]

Location / Zone [Insert Project Site / Zone]

00

Applicable Codes, Standards & Trade References

Jurisdiction: India (CPWD / BIS / NBC)

CPWD Reference	BIS / Indian Standards (IS Codes)	International Standards & Norms
CPWD Specifications Vol. 1 (Chapter 11: Marble Work & Flooring)	IS 1130 (Marble Blocks, Slabs and Tiles), IS 4126 (Code of Practice for Laying and Finishing of Natural Stone Flooring)	BS 5385-5 (Design and Installation of Terrazzo, Natural Stone and Agglomerated Stone Tile and Slab Flooring), ASTM C97 / C170

01

Purpose & Engineering Scope

Primary Trade: Italian / Natural Marble Laying & Polishing

This Method Statement defines the end-to-end procedure for dry-laying, book-matching, 6-sided pre-sealing, mortar bedding, resin/epoxy joint filling, 15-stage planetary diamond mirror polishing, and final penetrating sealer application for natural marble slabs (18–20 mm thick), modular stone patterns, and border bands.

02

Approved Materials, Tools & Equipment Schedule

Material & Plant Records

A. Permanent Materials TDS reference

Approved 18–20 mm Natural Marble Slabs (with intact fibreglass mesh net backing on fragile imported stones), OPC 43 Cement, Washed River Sand, White Cement (IS 8042), Solvent-Based UV-Resistant 6-Sided Stone Sealer, Two-Component UV-Stable Polyester/Epoxy Stone Resin Filler (Huntsman Araldite / Tenax / Akepox) or Epoxy Grout, Colour-Enhancing/Natural Penetrating Sealer (Aqua Mix Enrich 'N' Seal / Penetrating Sealer).

B. Tools, Plant & Measuring Instruments Calibration record

Wet bridge stone saw, 360° laser level, white rubber mallets, suction-cup lifters, heavy-duty planetary floor grinding/polishing machine (65–120 kg head pressure), diamond metal-bond and resin-bond Frankfurt/planetary grit pads (Grits #30 to #3000), wet vacuum extractor, digital glossmeter.

03

Pre-Execution & Substrate Preparation Checks

Pre-Work Checks

CHECK 3.1 CHECK

Dry Laying (Book-Matching) & Vein Approval

Unpack marble slabs in a designated well-lit dry-lay area. Arrange slabs and cut-to-size pattern modules strictly as per the approved flooring layout drawing, matching vein continuity and shade tone. Mark directional arrows and sequence numbers on the back/edge of each piece using non-staining chalk, and obtain written sign-off from the Architect prior to wet laying.

CHECK 3.2 CHECK

6-Sided Pre-Sealing (Dip / Brush Sealing)

Clean all cut marble pieces with clean water to remove cutting slurry and allow them to air-dry completely on racks (moisture content < 4%). Apply 2 coats of solvent-based UV-resistant anti-stain stone sealer on all 6 faces (top, bottom, and 4 cut edges) and allow 24 hours curing before laying to prevent moisture rising from the mortar bed.

APEX FITOUTS

Method Statement • Flooring & Stone Works

Natural Marble Slab & Pattern Flooring (6-Sided Pre-Sealing & 15-Stage Diamond Polishing)

Doc ID MS-FLR-005

Rev / Ver R0 / 2026.1

04

Step-by-Step Execution Methodology

Sequential Trade Operations (Steps 01 – 06)

STEP 01 EXECUTION

Reference Datum & Screed Bedding

Transfer the FFL datum around the room perimeter using a laser level. Clean the structural slab, apply a cement-polymer bond slurry, and spread a semi-dry 1:5 (or 1:4) cement-sand bedding mortar of 45–50 mm average thickness, compacted and screeded to 18–20 mm below FFL.

STEP 02 EXECUTION

Trial Seating & White Cement Slurry Floating

Place the pre-sealed marble slab onto the semi-dry mortar bed and tamp gently with a white rubber mallet until level with the laser datum.
Lift the slab using suction lifters to inspect the mortar bed footprint (ensuring 100% uniform bearing with zero voids).
Pour and trowel a 5–6 mm thick neat white cement slurry (or white polymer stone adhesive for resin-backed imported marble) over the bed, back-butter the slab underside, and lower the slab into its final position.

STEP 03 EXECUTION

Joint Alignment & Cut-Outs

Tamp the slab flush with adjacent pieces (paper-joint ≤ 1 mm or specified spacer width) with zero lippage. Execute precision wet-saw and core-drill cut-outs for floor boxes, drains, and thresholds. Cure the laid floor undisturbed for 48–72 hours.

STEP 04 EXECUTION

Resin / Epoxy Joint Filling

Rake out joints to full stone depth, vacuum clean, mask slab edges with low-tack tape, and fill joints and surface pinholes using colour-matched polyester/epoxy stone resin (e.g., Huntsman Araldite / Tenax) or Laticrete epoxy grout, leaving the filler slightly proud (0.5 mm) for grinding.

STEP 05 EXECUTION

15-Stage Planetary Diamond Grinding & Mirror Polishing

After 72 hours of resin curing, flood the floor with clean water and execute a 15-stage progressive diamond grinding, honing, and polishing sequence:

Stages 1–3 (Lippage Removal & Flattening): Metal/Hybrid Diamond Grits #30, #50, #100 to eliminate all joint lippage.
Stages 4–6 (Groove Removal & Grout Re-Pinholing): Resin Diamond Grits #120, #200, #400, followed by a secondary micro-grout pinhole filling pass using colour-matched liquid resin.
Stages 7–11 (Honing): Resin Diamond Grits #600, #800, #1000, #1200, #1500 (stop at #400/#800 if a Honed matte finish is specified).
Stages 12–15 (Mirror Polishing & Crystallization): Super-fine Resin Diamond Grits #2000, #2500, #3000 followed by white felt pad buffing with Italian polishing powder / crystallization compound until a deep, distortion-free mirror reflection is achieved.
Vacuum-extract all slurry between every single grit change so coarse grit particles never contaminate finer passes.

STEP 06 EXECUTION

Final Top Sealer Application

Wash the polished floor with pH-neutral stone cleaner, allow 24–48 hours to dry completely, and apply 2 coats of Aqua Mix Enrich 'N' Seal (or Penetrating Sealer) using a microfiber applicator pad, buffing off any unabsorbed surface excess after 15 minutes.

APEX FITOUTS

Method Statement • Flooring & Stone Works

Natural Marble Slab & Pattern Flooring (6-Sided Pre-Sealing & 15-Stage Diamond Polishing)

Doc ID MS-FLR-005

Rev / Ver R0 / 2026.1

05

Quality Assurance, Tolerances & Inspection Checkpoints (ITP)

Joint Inspection & Measurement Record

Ref	Inspection Stage	Acceptance Criteria / Tolerance	Verification Method	Gate
5.1	Dry-Lay & Pre-Sealing	Architect sign-off on vein matching; 6-sided sealer log verified before bedding.	Signed Dry-Lay Inspection	Review
5.2	Surface Flatness & Lippage	≤ 1.0 mm over 2.0 m straightedge; 0.0 mm joint lippage after grinding.	2m Straightedge & Feeler Gauge	Review
5.3	Gloss & Reflection	≥ 85–90 Gloss Units (GU) for mirror polish; uniform reflection of overhead light lines.	Digital Glossmeter (60°)	Review

06

EHS & Site Safety Controls

ISO 45001 & CPWD Safety Code

Safety Control 01 Mandatory

Route all wet-polishing slurry into a 3-stage sedimentation settling drum; never discharge marble slurry into building floor drains.

Safety Control 02 Mandatory

Use 30mA ELCB-protected waterproof industrial plugs for all wet floor-polishing machines.

Safety Control 03 Mandatory

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07

Technical Submittal Sign-Off & Execution Authorisation

Quality Control Record

Consultant Review Status:

A — Approved B — Approved as Noted C — Revise & Resubmit D — Rejected

Prepared & Submitted By CONTRACTOR

Authorized Signature & Company Stamp

Name:[Project Engineer / QA Lead]

Designation:APEX FITOUTS

Date:__ / __ / ____

Reviewed & Verified By PMC / QA-QC

Authorized Signature & Company Stamp

Name:[Resident Engineer / QA-QC]

Designation:Project Management Consultant

Date:__ / __ / 2026

Approved By CLIENT / ARCHITECT

Authorized Signature & Company Stamp

Name:[Lead Architect / Client Rep]

Designation:Design Consultant / Client

Date:__ / __ / 2026