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The Manufacturing and Maintenance of Ceramic and Porcelain Tile

Mass Produced Tile

There are two basic types of tile: ceramic and porcelain. The most common (and also the less expensive) is ceramic. Ceramic is baked clay which is either glazed or non-glazed.

Glazed Ceramic

First, the clay is selected, ground to a fine grain size, cleaned, and moistened. The clay is kneaded to remove any air bubbles and then pressed and formed. If the tile is undergoing a typical double-firing process, the formed clay is fired (baked) once, the glaze is applied and the tile is baked again. Glazing gives a tile better resistance to water and stains and makes the surface look brighter and more vibrant. Glazed tile can also become slippery when wet, so if you are considering using the tile for flooring, be sure to check the glaze porosity.

Unglazed Ceramic

This category includes tiles such as quarry or terra-cotta. Unglazed ceramic has a rustic, earthy natural look. This type of tile undergoes the same procedure as noted above, but is fired without glazing. Sometimes the tile is fired twice to help seal the surface more completely. Unglazed tile is harder to keep clean than glazed tile, as the “open” surface will hold dirt. For this reason, most consumers choose darker colors when installing unglazed tile.

Porcelain Tile

This type of tile is finely ground ceramic made of a mixture of clays and minerals similar to those found in fine vases and dinnerware. The mixture of these fine clays allow porcelain tile to be fired at incredibly high temperatures (even higher than ceramic tile). The typical firing temperature exceeds 2,400° F. This higher firing temperature results in a tile that is much denser that standard ceramic. While it does cost more, porcelain resists stains and moisture, and is very easy to clean. The surface also has a more lustrous appearance, much like costly granite or marble.

Handmade Tile

Due to the labor involved in making handmade tiles, these tiles are more costly than the mass-produced tiles and should be looked at as more of an “art form.” There are many variations of creating tiles by hand – each as different as the artist himself. However, we will address the most commonly used method here for bas-relief type tile, where the design is carved into the tile itself, not just painted on.

Every tile starts with an original carving done in wax, porcelain or wood. Once the carving is completed, a plaster mold is taken from it.

Ceramic clay is then hand-pressed and formed into the mold. Often times, a plastic mallet will be used to make sure the clay adheres to every crevice of the mold. Once the clay has been formed, the molds are removed and the tiles are slowly dried to help prevent cracking and warping.

Once dry, the tiles can be handpainted (or left unpainted) and fired at 2000° F. The tile is now dense and if painted, the colors are permanently bound to the tile. Most handmade tiles will be glazed at this stage. Sometimes an antiquing stain is applied first, and allowed to settle into the recesses the tile, with the excess being removed. Once glazed or stained, the tile is fired again. The tile will now have an almost “glassy” appearance and is stain and water resistant.

Maintenance

One of the great benefits of tile is its easy maintenance. Remove visible soil with a broom, non-oily dust mop or even a vacuum cleaner set on the lowest setting. Damp mop as needed using a standard household floor cleaner. Bleach is not generally recommended as it can discolor the grout.

Research taken from the following sources:

Vandervort, Don. “ Ceramic Flooring Tile ”. www.Hometips.com. May 25, 2006.

Read, Philip. “Art Tiles: Aesthetics of Pleasure,” Mountain Path Studio. 2006

Grimmer, Anne E. and Konrad, Kimberly A. “Historic Ceramic Tiles,” www.OldHouseWeb.com. May 24, 2006.