Tile | How It's Made
Being familiar with ceramic tile construction helps you
understand and evaluate its performance aspects: why certain
ceramic tile floors wear better and longer. The main ingredients
of ceramic tile and its general manufacturing process have not
changed that much throughout the centuries. All ceramic
tiles are created from natural products extracted from the earth
that are shaped into tiles and then fired in kilns at extremely
high temperatures.
2 main types of tile construction:
Glazed
- from the side, see 2 layers
- body – called the bisque
- top layer – called the glaze
- hard non-porous, impermeable surface after firing
- more stain resistant than unglazed
- easy to clean
- consider for areas like the kitchen and baths
Unglazed
- solid colored all the way through
- do not have a top layer of glaze
- referred to as through-body construction
- no additional surface applications
- more dense and durable than glazed
- suitable for interior and exterior applications
- good for areas with kids
There are 5 steps in the ceramic tile manufacturing process:
Mining
- process begins with the mining of the raw materials
- mixture composed of clay and minerals
Blending and Mixing
- introduces mud into the mix
- clay and mineral mixture blended and mixed into a semi-fine
powder
- water is added to form a wet slurry or mud-like
consistency
- the slurry is pumped into a large dryer
- result- fine clay powder that feels like warm, fine sand
Pressing
- applies pressure to the process
- clay is pressed or formed into a tile shape
- pressed tiles are called green tiles
- another method called extrusion replaces the
pressing step
- extruded tiles are formed by forcing the clay through a mold
versus pressing the tile
- pressing is the more common method used today
- after the green tiles are formed they are dried
Glazing
If the tile is to remain unglazed it skips this step and goes
directly to the firing kiln.
- liquid is prepared from a glass derivative called
frit and colored dyes
- applied by a high-pressure spray or poured onto the tile
Firing
- fired in the kiln at temperatures around 2,000 degrees
Fahrenheit
-
monocoturra tile or single fired -tiles that
are fired once after the glaze is applied
-
biocuttura or double fired- first fired after
the green tile is dried and fired again after the glaze
is applied
Alternative- porcelain
- made up of 50% feldspar
- fired at a much higher temperature
- harder and denser
- high performance
- low water absorption ratings of less than 0.5 percent
- can be used for interior and exterior applications or
commercial areas
After the finished tiles have been inspected for quality
assurances, they are packaged, crated and ready to be
shipped.
Uses
- not all ceramic tile is suitable for each area of your home
- tile on your kitchen backsplash may not be recommended for
installation on the floor
Rating System
- rating system provided
- rating system found on samples or boxes
- most common system rates ceramic tile abrasion resistance or
the overall durability of the tile
5 Classes
Class 1: no foot traffic
- interior wall applications only and not for the floor
Class 2: light traffic
- interior wall applications and for residential bathroom
flooring only
Class 3: light to moderate traffic
- for residential floor and wall applications including
bathrooms, kitchens, foyers, dining rooms and family rooms
Class 4: moderate to heavy traffic
- residential, medium commercial and light industrial floor
and wall applications including shopping malls, offices,
restaurant dining rooms, showrooms and hallways
Class 5: heavy/extra heavy traffic
- can be installed anywhere
Slip Resistance Rating
- measured by its Coefficient of Friction (COF)
- higher the COF the more slip resistant the tile
- important for areas that get wet
Other ratings
- scratch resistance
- moisture absorption
- chemical resistance
- breaking strength