Formats such as 60 × 120, 120 × 120 or 120 × 260 cm are heavy, flexible and unwieldy. Without vacuum lifters, they are hard to transport and place cleanly. This guide shows how many units you need for which format, when a lifting frame becomes necessary and how to achieve a flat, void-free surface with buttering and floating, vibration and a leveling system.
Weight and handling of common formats
Porcelain stoneware weighs about 24 kg per square meter at 10 mm thickness. That makes it easy to classify the common formats:
| Format | Thickness | Weight | Gripsters | People |
|---|---|---|---|---|
| 60 × 120 cm | 10 mm | approx. 17 kg | 2 | 1 |
| 120 × 120 cm | 10 mm | approx. 35 kg | 2 to 4 | 2 |
| 120 × 260 cm | 6 mm | approx. 45 kg | Lifting frame with 4 to 6 suction pads | 2 |
| 120 × 260 cm | 12 mm | approx. 90 kg | Lifting frame with 6 to 8 suction pads | 3 to 4 |
With large formats, the real problem is rarely the weight, but the bending. A 6 mm panel 2.6 m long weighs only 45 kg, yet it breaks if it is lifted flat at a single point. The guide How to assess load capacity correctly shows how to calculate the weight of other formats and materials.
How many vacuum grippers you need
60 × 120 cm: Two gripsters, each about a quarter of the panel length from the end. With one unit in each hand, one person can lift the panel, set it down and align it in the adhesive bed. A single vacuum gripper in the middle is not enough: the ends swing and the panel cannot be guided cleanly.
120 × 120 cm: Two people, each with one or two vacuum grippers. When placing the panel in the adhesive bed, both hold it on opposite sides so it is lowered evenly.
120 × 260 cm and larger: This calls for a lifting frame. Individual vacuum grippers do not distribute the load evenly enough, and the panel sags between the holding points.
The database lists 151 models for large formats. They have a median price of €70 and a load capacity of 220 kg, and 30% of the electric models have an automatic re-pump. Since two units are needed from 60 × 120 cm anyway, twin packs and sets are worth a look: they cost a median of €44 per unit. You will find suitable models under Gripsters for large formats.
Lifting frames and transport aids
A lifting frame consists of aluminum profiles that can be adjusted to the panel format. Four to eight suction pads and several handles are mounted on it. The frame keeps the panel rigid across its whole surface and prevents it from sagging while being carried or turned. Many frames can be swiveled together with the panel from vertical transport to horizontal, so the panel can be lowered directly over the adhesive bed.
For longer distances, slab trolleys are added, on which the panel is moved on edge or in the frame. Large panels are cut on a cutting system with continuous support, never unsupported in the air. The guide Vacuum gripper, panel carrier or carrying strap? gives an overview of the alternatives.
Storing panels on site
Large panels are stored on edge, against a sturdy rack or a wall, at a slight angle and on timber battens or rubber blocks. Lying flat on uneven ground, a thin panel can break just from someone stepping on a corner. Leave the panels in their original packaging until you need them, and take them straight from the stack with the vacuum grippers. Plan the route from the storage area to the installation spot in advance: with a length of 2.6 m, door widths, stairs and corners decide whether a panel reaches its destination in the frame or only on edge on the trolley.
Preparing the substrate and adhesive
Large formats demand a flatter substrate than small tiles. Irregularities that disappear in the adhesive bed at 30 × 60 cm show up at 120 × 260 cm as voids or lippage. Check the substrate with a long straightedge and fill hollows with leveling compound before laying.
The buttering and floating method has proven itself for laying:
- Floating: Spread the tile adhesive on the substrate with a notched trowel, for large formats usually with a 10 to 12 mm notch. Comb all ridges in the same direction, ideally parallel to the short side of the panel.
- Clean the back: Wipe dust and release agent residue off the back of the panel with a damp sponge.
- Buttering: Apply a thin contact layer of adhesive to the back with the flat side of the trowel.
- Placing: Lay the panel within the open time of the adhesive. If a skin has already formed on the adhesive, spread it again.
A deformable flexible adhesive is suitable, for thin large formats one of class C2 with S1.
Placing and vibrating the panel
First place the panel with one edge against the neighboring panel or the joint marking, then lower it evenly. Then slide the panel back and forth a few millimeters across the adhesive ridges. This collapses the ridges and lets the trapped air escape.
This is where the vibration function comes in. 19 models in the database have it, all with an oval suction plate. They have a median price of €77 and a median load capacity of 250 kg, and 95% run on a removable battery. The vacuum gripper is placed on the panel as it lies in position, and the vibration compacts the adhesive bed and closes voids. Work from the center of the panel toward the edges and reposition the unit several times. Vibrating too long in one spot pushes the adhesive aside and can make the panel sink on one side.
Without vibration, you reach the same goal by pressing the panel down flat by hand or with a rubber mallet over a wooden batten, just more slowly. Vacuum grippers with vibration function and the guide Bedding in tiles with a vibration function offer an overview.
Check adhesive coverage at the start: lift one of the first panels off again and inspect the back. The adhesive should adhere over almost the entire surface. If dry spots appear, adjust the notch size, adhesive consistency or vibration.
Leveling
With large formats, even small height differences between adjacent panels are noticeable, especially in raking light. A leveling system prevents such lippage:
- Clips or straps are slid under the panel edges at intervals of about 25 to 40 cm.
- Wedges or screw caps pull the edges of both panels to the same height.
- Joint width: The clips also set the joint, usually 2 to 3 mm for rectified large formats.
The leveling system evens out offsets at the edges, but not an uneven substrate. Once the adhesive has cured, the clips are knocked off with a rubber mallet in the direction of the joint.
Typical mistakes
- One vacuum lifter for a long panel: The panel sags and can crack.
- Carrying flat without a frame: Thin large formats are carried on edge or in a frame.
- Dusty back: The adhesive does not bond, and voids form.
- Adhesive that has skinned over: The panel only adheres in spots.
- Ignoring the vacuum display: Before every lift, check the display and do a short test lift, as described in the guide Working safely with vacuum lifters.
A vacuum lifter, often called a gripster in the trade, is no substitute for careful preparation. But it is what makes setting down, aligning and readjusting large panels truly precise.
Frequently asked questions
How many gripsters do I need for a 120 × 260 cm panel?
For this format, a lifting frame with four to six suction pads is recommended at 6 mm thickness, and six to eight at 12 mm. Individual vacuum grippers do not distribute the load evenly enough. A 6 mm panel weighs about 45 kg and is carried by two people; a 12 mm panel, at about 90 kg, by three to four.
Does the vibration function replace buttering and floating?
No. Vibration compacts the adhesive bed and helps close voids. But full coverage only comes from combining adhesive on the substrate with a thin contact layer on the back of the panel. Vibration complements this method; it does not replace it.
Can I lay large formats on my own?
Up to 60 × 120 cm, this is quite feasible with two vacuum grippers; at 10 mm thickness, the panel weighs about 17 kg. From 120 × 120 cm, two people should work together, because weight and size make it nearly impossible to lower the panel evenly alone. Formats such as 120 × 260 cm need a lifting frame and at least two people.