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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