f6john, you’re right that it takes a lot of mortar! I am about 3/4 done with putting porcelain tile down in my new workshop, which is 30’ x 40’. In previous garages I have had plain concrete, epoxy, Race Deck, and polyurea and haven’t been really satisfied with the durability and clean-ability of any of them. Inspired by this thread’s clear guidance, and since this will be my last and “forever” shop, I decided to take the plunge. I am doing the work, and I will confess that there are times when I wondered “what was I thinking?”
It’s a big project for an amateur, but I am retired so I am taking it one 50 lb bag of mortar at a time. I brought home 2 & 1/2 tons of 12”x24” tile from Floor and Decor. It’s PEI 4, at $1.28 sf. So far, I’ve bought 1 ton (40 bags) of large format tile mortar. Laying down mortar, and back buttering every tile with the 1/2" notched trowel does use a lot of mortar. And I think I will need 5 or 6 more bags before I am done. I'm taking it on faith that doing it this way, as advised by Dakota, provides full support for every tile and gives enough mortar base to make sure that tiles are level and even, with the minimum amount of lippage, with I now know can be a challenge with large format tile. But, based on results up to now, I am thrilled with how it's coming out. I completed the first half with grout and sealer, before moving everything that’s in the shop so far, to that side, to work on the other side. It’s good looking, and I expect it to hold up well to everything I throw at it, spills and heavy drops included. I will be putting in a 2 post lift when it is done. Here’s a shot of the first half:
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And here is one of the other side, as of today. I figure another couple of weeks and I'll be done with the tile, and I can get on with moving in and setting up the shop.
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I'd like to give major props to Dakota for posting this thread with so much practical and useful advice. Thank you!! It definitely gave me the confidence that porcelain tile was what I wanted to do, and enough practical tips to keep me out of trouble. Of course reading the tech info from the mortar and grout suppliers makes a difference too (Mapei, in my case).
I think any pretty competent DIYer can do this with some patience and taking it one step at a time. And, don't forget a really good set of knee pads!