Terrazzo flooring is a type of flooring material that is composed of various chips of materials like marble, quartz, granite, glass, or other suitable materials. These chips are mixed with a cementitious or polymeric binder to form a composite material. The mixture is then poured onto the flooring surface, which can be a concrete slab or other suitable substrate, and allowed to harden.
Once the terrazzo mixture has hardened, the surface is ground and polished to produce a uniformly textured and smooth finish. This process helps to create a durable and long-lasting flooring material that is ideal for high traffic areas such as commercial buildings, schools, hospitals, and airports.
Terrazzo flooring is known for its aesthetic appeal and versatility. It is available in a wide range of colors and patterns, making it an ideal flooring material for both traditional and modern settings. The flooring’s durability and low maintenance requirements make it an excellent choice for areas that experience heavy foot traffic.
In summary, terrazzo flooring is a composite material made up of chips of various materials mixed with a binder and poured onto a flooring surface. The flooring is then polished to create a smooth and uniform finish, resulting in a durable and attractive flooring option suitable for various settings.
The procedure/methodology to lay the terrazzo flooring is discussed in the article below-
Materials of Terrazzo Flooring
1. Aggregate
Terrazzo flooring is composed of aggregates that are made up of chips of marble, quartz, granite, glass, or other suitable materials. The size of these chips can vary from 1 mm to 25 mm. The topping layer of the terrazzo flooring is made up of marble powder, which must pass through the 300-micron sieve.
The aggregates used in the topping layer of the terrazzo flooring must meet certain specifications. They should be hard, sound, dense, and homogeneous in texture, with coarse grains that are crystalline in nature. Furthermore, they must be uniform in color and free from stains, cracks, decay, and weathering.
It is important to ensure that the aggregates used in the topping layer of the terrazzo flooring meet these criteria. By doing so, the resulting flooring will be strong and durable, with a smooth and uniform surface. These features make it an ideal choice for flooring in a variety of settings, from commercial spaces to residential homes.
2. Color Pigments
The terrazzo flooring requires the use of color pigments that are permanent in nature. In order to ensure this, it is necessary to carefully select the appropriate pigments that will maintain their color over time. The proportion of color pigment that is mixed with the cement must also be in accordance with the specifications outlined in Table 1. This is important in order to achieve the desired color and consistency of the terrazzo flooring. By adhering to these requirements, it is possible to create a high-quality, long-lasting terrazzo flooring that is both aesthetically pleasing and durable.
Table 1: Cement pigment proportion for various colors of matrix in Terrazzo flooring
| Colour of cement | Pigment to be used | Proportion of pigment | Proportion of cement | Proportion of white |
| Red | Red oxide of iron | 1 | 15-20 | Nil |
| Black | Carbon black | 1 | 25-40 | Nil |
| BottleGreen | Green Chromium oxide | 1 | 15-30 | Nil |
| Pink | Red oxide | 1 | Nil | 100-300 |
| Cream | Yellow oxide of iron | 1 | Nil | 100-400 |
| Yellow | Yellow oxide of iron | 1 | Nil | 25-75 |
| Light Green | Green chromium | 1 | Nil | 50-150 |
| French Grey | — | Nil | 1 to 2 | 1 |
| Fawn | Yellow oxide of iron | 1 | 6 | 4 |
3. Dividing Strips
The material used for flooring must have the same level of wear resistance as the flooring material itself. Additionally, dividing strips must be made of materials such as aluminum, brass, copper, glass, plastic, or other similar materials. To ensure durability, these strips must be coated with bitumen. The size of the strip must be at least 1.5mm thick and 25mm wide.
General Specification of Terrazzo Flooring
Terrazzo flooring is a type of flooring that consists of two layers. The first layer is known as the base layer or cushioning layer and is typically made of concrete. The second layer is the top layer and is made up of terrazzo aggregates. The way in which the layers are arranged will vary depending on whether the flooring is being laid over the ground or on a structural slab.
If the terrazzo flooring is being laid over the ground, it will consist of the two layers mentioned above. The base layer of concrete or cushioning layer will be placed directly on the ground, followed by the top layer of terrazzo aggregates.
On the other hand, if the flooring is being laid on a structural slab, the arrangement will be different. Figure 3 shows an example of the arrangement for this type of terrazzo flooring. The base layer of concrete or cushioning layer will be placed on top of the structural slab, followed by a layer of insulation. Finally, the top layer of terrazzo aggregates will be added to complete the flooring.
Regardless of the arrangement, terrazzo flooring is a popular choice due to its durability and versatility in design.
The specifications for the construction of flooring involve the use of sand for the sub-base. This sand must be well compacted to ensure stability. A cushioning layer made of lime concrete is preferred for added protection.
As for the base course, dry lean concrete with a 1:5:10 ratio should be used, and it must have a minimum thickness of 100mm.
The underlayer and topping for the flooring must have a combined thickness of at least 30mm. This ensures that the flooring will be sturdy and durable.
Finally, the terrazzo topping layer must have a minimum thickness based on the size of the chips used, as indicated in Table 2. By following these specifications, the flooring will be able to withstand regular use and last for an extended period.
Table 2: Size of chips and thickness of topping layer.
| Size of chips (mm) | Minimum thickness (mm) |
| 1 to 2 2 to 4 | 6 |
| 4 to 7 | 9 |
| 7 to 10 | 12 |
| > 10 | not less than 1 1/3 times the maximum size of chips. |
Mix Proportion of Underlayer and Topping Layer
The specification for the underlayer requires a mix proportion of cement concrete in the ratio of 1:2:4 by volume, with the maximum aggregate size not exceeding 10mm.
As for the terrazzo topping layer, the mix proportion requires three parts of cement to one part of powder by mass.
Table 3 provides the necessary proportions of aggregates for the cement marble powder mix based on the size of the aggregates. These proportions must be followed for every part of the mix.
Table 3: Proportion of aggregate depending on the size of aggregate.
| Size of aggregates parts (mm) | Proportion of aggregate of binder mix |
| 1 to 7 | 1 ¾ |
| 7 to 1515 to 22 | 1 ½ |
4. The proportions of cement shall be inclusive of any pigments added to the cement.
Procedure of Laying In-situ Terrazzo Flooring
1. Mixing of Materials
To achieve a uniform appearance in terrazzo work, it is crucial to mix the materials thoroughly. When different colored chips are used, it is recommended to mix them well in the required proportions of various colors and sizes. When using white cement, it is necessary to sieve and mix the pigment and cement in the required proportions with marble powder and aggregates. During mixing, the aggregates must not be heaped, as this can cause the coarsest chips to move to the edge of the pile while the cement settles to the center at the bottom.
To ensure a proper mix, the dry ingredients should be thoroughly mixed first, and then water should be added in small quantities to achieve the desired consistency. Machine mixing is preferred for mixing, but a common type of concrete mixer is not as suitable for terrazzo work as a mixer specifically designed for this purpose. The special mixer prevents segregation by using blades.
It is important to note that the pot life of the mix is not more than half an hour after the addition of water during preparation. This means that the mix must be laid within this time frame. Failure to do so may result in the mixture becoming unusable and needing to be discarded.
Under-Layer of Terrazzo Flooring
The specified design mix for cement concrete must be utilized for this project, as previously discussed in the design mix section. It is important to note that the panels being used should be of a consistent size, with a maximum area of two square meters or a maximum length of two meters for indoor situations. However, in exposed situations, the length of any side of the panel should not exceed 1.25 meters to ensure stability and durability.
Before laying the underlayer over the cement concrete or RCC base, a cement slurry must be applied at a rate of 2.00 kilograms per square meter. This step is crucial to ensure proper adhesion and bonding between the underlayer and the base material. By following these guidelines, the project can be completed with a high level of quality and integrity.
Fixing of Strips.
The specified task involves fixing strips of different materials with specific thicknesses at the appropriate level to achieve the required slope. The options for materials include glass, asbestos, PVC, aluminum, and brass. These materials have varying thicknesses of 4mm, 5mm, and 2mm, respectively.
To achieve the desired result, the chosen strips must be affixed with their tops at the correct level to ensure proper slope. Additionally, if necessary, strips made from stone, marble, or any other material of the specified thickness can also be used.
In summary, the task at hand involves fixing strips of varying materials and thicknesses to achieve the required slope. The strips must be affixed at the proper level to ensure proper drainage, and other materials may be used as needed to achieve the desired result.
Laying of Topping Layer of Terrazzo Flooring
To create terrazzo, various materials such as topping materials, coloring material, cement, marble powder, and marble chips are dry mixed together. It is important to ensure that they are mixed thoroughly for even distribution. Once the dry mixture is ready, water is added gradually through fine sprays to create a stiff and workable mortar. The mixture should be homogeneous, meaning the different components are evenly distributed throughout the mixture.
It is crucial to lay the terrazzo topping layer at the right time. The underlayer should be hard enough to prevent the cement from traveling to the surface, but still plastic enough to be workable. The topping layer should be slightly thicker than specified, which will allow for uniform thickness after compacting.
To achieve the desired thickness, the surface must be troweled and pressed using a straight edge and steel floats. During this process, it is important to ensure that the marble chips are spread evenly and are visible on the surface. The aim is to maximize the visibility of the marble chips, while still achieving a smooth and level surface.
Polishing, Curing and Finishing of Terrazzo Topping Layer
The top layer polishing process must be done by machine means no earlier than 36 hours after laying the top layer. To achieve an even and smooth surface, the machine used should be equipped with special rapid cutting grit blocks of coarse grade. This machine will water and grind the surface until the marble chips are evenly exposed, resulting in a smooth floor.
Once the first grinding is completed, the surface must be washed thoroughly to eliminate any grinding mud that may remain. A cement and coloring matter grout mix in the same proportion and mix as the topping will then be applied to fill any pinholes that appear. The surface will be left to cure for 5 to 7 days before being rubbed again with a machine fitted with fine-grit blocks. It will then be cured once more for three to five days.
Finally, the third grinding will be performed using a machine fitted with fine-grade grit blocks. The purpose of this final grinding is to achieve an even and smooth surface without any pinholes.
FAQs on Terrazzo Flooring
1. What is terrazzo flooring?
Terrazzo flooring is a type of flooring material that is made by combining chips of various materials such as marble, quartz, granite, glass, and others with a cementitious or polymeric binder. The mixture is then poured onto a surface and allowed to settle to form the flooring. Once the flooring has been poured, it is then ground and polished to produce a smooth and uniform texture. This process helps to create a durable and attractive flooring option that can be used in a variety of settings.
2. What are the advantages of Terrazzo Flooring?
Terrazzo flooring offers several significant advantages that make it a popular choice for both residential and commercial spaces. One of the most notable benefits is its exceptional durability, which results in a long lifespan for the flooring. Additionally, Terrazzo flooring provides a wide scope for new designs, allowing for customization and creativity in the design process.
Another advantage of Terrazzo flooring is its environmental friendliness. The flooring is made from a mixture of natural materials, including marble chips, glass, and cement, making it an eco-friendly choice compared to other flooring materials. Finally, Terrazzo flooring is highly resistant to scratches, stains, and damage from foot traffic, making it an ideal choice for high-traffic areas or areas that are prone to spills and stains. Overall, Terrazzo flooring provides an excellent combination of durability, versatility, and environmental sustainability.
3. Are Terrazzo Flooring costly to construct?
The construction cost of terrazzo flooring is on the higher side when compared to marble or granite flooring as it involves both marble and granite chips, cement, and resin as adhesive and the installation process shall be carried out by professionals and skilled masons.
4. Are terrazzo Flooring durable?
Flooring materials have a limited lifespan, and with time, they deteriorate. However, the terrazzo flooring has proven to be more durable than other flooring options such as marble or stone flooring. This is due to the unique composition of terrazzo flooring, where chips of marble or stone are set in a concrete or resin matrix, creating a strong and resilient surface.
Compared to other flooring materials, the strength and durability of terrazzo flooring are significantly higher. The chips of marble or stone used in terrazzo flooring are firmly embedded in the concrete or resin matrix, which makes the flooring more resistant to scratches, chips, and cracks. This durability ensures that terrazzo flooring can withstand heavy foot traffic and wear and tear, making it an ideal choice for high-traffic areas such as airports, malls, and hospitals.
In addition to its durability, terrazzo flooring is also highly resistant to stains and is easy to clean. The surface is non-porous, which means that it does not absorb liquids, making it resistant to stains caused by spills. This feature ensures that terrazzo flooring maintains its aesthetic appeal over an extended period.
In conclusion, terrazzo flooring is an excellent flooring option that guarantees durability and aesthetic appeal. Its unique composition makes it more durable than other flooring materials, and its stain-resistant feature makes it easy to maintain. For anyone looking for a long-lasting and low-maintenance flooring solution, terrazzo flooring is a great choice.