In the ever-expanding Humble Independent School District (ISD) near Houston, Texas, a new middle school is rising, designed to support future generations of students in a fast-growing region. Known as Lake Houston Middle School (Humble Middle School #11), this expansive facility represents more than just classroom space—it’s a study in design sophistication, large-format tile installation and high-performance materials.
Helping lead the charge in this multi-surface endeavor was Westway Flooring, which turned to MAPEI for a full system of tile installation products that could keep up with the ambitious project scope.
“This wasn’t a typical school tile job,” explained Gary Sharpe, Project Manager with Westway Flooring, an NTCA Member tile contracting company. “We had to install tile up to 24’ [7.32m] high, manage massive 3’ x 10’ [0.91m x 3.05m] Laminam panels in interior and exterior settings, and coordinate it all while keeping up with the overall construction schedule. MAPEI’s products and support made the difference.”
Building from the ground up
Construction on Lake Houston Middle School began in September 2024, with tile installation scheduled to wrap up in May 2025. The project included the installation of porcelain tiles in a variety of formats—from 2” x 8” (5cm x 20cm) accent tiles to large-format 12” x 24” (30cm x 61cm) porcelain tile, to expansive Crossville Laminam porcelain panels measuring 3’ x 10’ (0.91m x 3.05m).
In total, the tile installation included:
- 4,000 sq. ft. (372 m2) of 6” x 6” (15cm x 15cm) quarry tile with epoxy grout.
- 24,100 sq. ft. (2,239 m2) of 6” x 24” (15cm x 61cm) wood-look porcelain tile.
- 45,300 sq. ft. (4,208 m2) of 12” x 24” (30cm x 61cm) porcelain tile on walls and floors.
- 8,550 sq. ft. (794 m2) of 2” x 8” (5cm x 20cm) accent wall tile.
- 6,000 sq. ft. (557 m2) of 3’ x 10’ (0.91m x 3.05m) Crossville Laminam panels in various colors and thicknesses.
“Projects of this scale really showcase how important it is to have a complete system from one manufacturer,” said Rick Hay, MAPEI Sales Representative. “From surface prep to waterproofing to the adhesives and grouts, we were able to provide Westway Flooring with solutions at every step.”
MAPEI’s complete system solutions
MAPEI products were used throughout the installation, starting with surface preparation. In areas where the concrete subfloor required leveling, Novoplan 2 Plus high-strength, self-leveling, cement-based underlayment and repair mix was applied to create a smooth, stable base. For crack isolation, Mapelastic CI premixed, liquid-rubber, quick-drying crack isolation membrane was used, and wet areas such as restrooms received Mapelastic AquaDefense, a premixed, advanced liquid-rubber, extremely quick-drying waterproofing and crack isolation membrane for waterproofing protection.
“One of the great things about working with MAPEI is the reliability of the systems,” said Charlie Patterson, MAPEI Sales Representative. “Contractors can trust that the products will perform—and if there are questions, we’re here for them.”
The setting materials were carefully selected based on tile size and substrate. For the bulk of the porcelain tile installation, Keraflex SG (Gray) standard-grade, extra-smooth, large- and heavy-tile mortar with polymer provided the strength and open time needed. For the large-format 3’ x 10’ (0.91m x 3.05m) panels, installers used Keraflex Super (White) premium, extra-smooth, large-and-heavy-tile, nonsag/nonslump mortar with polymer and no VOCs—and it exceeded expectations.
“We worked with the architect and were able to get Keraflex Super approved specifically for the Laminam panel installs,” Sharpe said. “The workability and strength were ideal for those large panels, and it helped us stay on schedule.”
Grouting was also tailored to each application. Ultracolor Plus FA high-performance, rapid-setting grout was used in most standard tiled areas, while Kerapoxy CQ premium two-component,100%-solids, epoxy grout was used in commercial kitchens and high-moisture spaces.
Mapesil T Plus professional-grade, 100%-silicone sealant was used at expansion joints and floor transitions, and Keracaulk U premium, unsanded siliconized acrylic caulk was used at vertical corners and door jambs.
Overcoming installation challenges
Installing tile at heights of 24’ (7.32m), including vertical accent tile and large porcelain panels, presented unique challenges for the Westway crew. Working from manlifts, mechanics and helpers used trowel-applied mortars while harnessed in full three-point safety gear.
“Safety was a big concern,” Sharpe said. “But our team was trained and experienced, and MAPEI’s products had the workability and bond strength we needed to get those tiles installed securely and safely.”
Equally complex were the “portals”—large vertical tile installations in 11 areas throughout the school that had to be coordinated with adjacent trades.
“Those portals took careful planning,” Sharpe said. “But with the right MAPEI materials and a coordinated effort from all involved, we made it work.”
A trusted partnership
Westway Flooring’s longstanding relationship with MAPEI proved crucial throughout the project. Product availability, performance, and technical support were all instrumental in keeping the job on track.
“There were days when we needed a specific grout or mortar the next day, and MAPEI came through every time,” Sharpe said. “That kind of local product availability and responsive support is why we choose to work with MAPEI.”
Hay echoed the sentiment. “Westway is a top-tier installer, and when you pair their craftsmanship with MAPEI’s system solutions, the results speak for themselves.”
With its complex design, large-format tiles, and vertical installations, Lake Houston Middle School pushed the boundaries of traditional school construction. Thanks to the skilled team at Westway Flooring and the comprehensive support from MAPEI, the project is set to be completed on time and to the highest standards.
“This is one of those projects that makes you proud,” Patterson said. “It highlights the craftsmanship of our contractor partners and shows how MAPEI’s system solutions can meet any challenge.”
Lesley Goddin has been writing and journaling since her first diary at age 11. Her journey has taken her through a career in publishing and publicity, landing her the editor position of TileLetter and its special publications in 2006. Her goal is to educate, inspire, recognize and encourage those in the tile industry -- especially the tile and stone contractor.
