How to Install Quarry Tiles: A Complete Guide
Quarry tiles are a traditional and durable paving choice, widely used across the UK in both domestic and commercial projects. One of the best-known manufacturers is Ketley Brick, whose factory produces some of the country’s most respected quarry tiles.
Renowned for their low water absorption (≤ 3%, and in some cases as little as 1.5%), quarry tiles provide excellent frost resistance. Their dense, hard-wearing properties make them resistant to acids, alkalis, oils, and grease, making them a reliable choice for patios, driveways, and terraces.
For external paving, quality quarry tiles should achieve:
- Slip resistance: Pendulum Test Value (PTV) ≥ 36 in wet conditions (≈ R11).
- Flexural strength: ≥ 22 N/mm².
- Abrasion resistance: Class 4–5.
- Chemical and thermal shock resistance for year-round durability.
Better-quality tiles are through-body, meaning the colour and material run throughout the thickness rather than being surface-coated. Standard thickness is around 18 mm, though some ranges vary from 12–25 mm.
Base Construction
The correct base is critical when learning how to install quarry tiles. These tiles should be laid on a 100 mm thick C30 reinforced concrete slab, cured for at least six weeks.
Recommended build-up for an outdoor patio or terrace:
- Excavate to ~225 mm.
- Compact subgrade to falls of 1:60 (≈ 1.7%).
- Install a non-woven geotextile membrane.
- Lay and compact 100 mm MOT Type 1 sub-base.
- Cast 100 mm C30 reinforced concrete with A142 mesh.
- Remove air pockets with a vibrating poker; finish with tamped/brushed finish (avoid power-float).
- Ensure a fall of 1:60 is built into the slab.
- Once cured, apply a damp-proof membrane and primer if required.
Key Notes:
- Leave a 10 mm gap between slab and property walls.
- Expansion joints every 4–6 m are essential.
- Structural contraction joints should align with tile joints and be sealed with colour-matched silicone.
Materials
- Adhesive: Cement-based, polymer-modified, frost-resistant (C2 S1).
- Grout: Flexible, frost-resistant, cement-based (CG2).
- Sealant: External-grade, flexible polyurethane or silicone.
- Sealer (optional): Impregnating sealer for added stain resistance.
Tools & Equipment
- Buckets, mixing paddle, straight edge, spirit level.
- Notched trowel (10–12 mm).
- Rubber mallet, tile spacers, pointing gun.
- Tile cutting tools with diamond blade.
- Washboy and sponge.
Installation Sequence
Substrate Preparation
- Ensure the base is sound, cured, frost-free, and has correct falls.
- Remove laitance mechanically if required.
Setting Out
- Dry lay tiles to check alignment.
- Ensure no edge cuts are smaller than half a tile.
- Use stringlines for accurate jointing.
Fixing Tiles
- Apply adhesive with a notched trowel for 100% coverage.
- Back-butter tiles (BS 5385-3:2024).
- Bed tiles with a slight wiggle motion to remove voids.
- Maintain joints of 5–10 mm.
Movement Joints
- Provide joints at 3–4.5 m centres.
- Install perimeter joints at abutments and changes of plane.
- Fill with external-grade sealant.
Grouting
- Allow adhesive to cure (≈24 hrs).
- Apply grout with a rubber float, cleaning promptly.
- Use colour-matched silicone where grout meets expansion joints.
Cleaning & Sealing
- Clean with pH-neutral cleaner once dry.
- Optional impregnating sealer may be applied.
Protection
- Protect area from frost, rain, and traffic during curing.
- Keep barriers in place until fully cured.
Maintenance
Quarry tiles are low-maintenance. Simply brush regularly and occasionally wash down with a light power washer. Always dampen the surface before applying cleaners to avoid absorption. Repair damaged grout or tiles promptly to maintain performance.
Conclusion
Quarry tiles are a timeless, robust paving solution, but their success lies in proper preparation and installation. By following the correct how to install quarry tiles process — from reinforced base construction to careful grouting — you can achieve a long-lasting, frost-resistant surface suitable for patios, driveways, and terraces.
