TILESTILES

ABHINAYA ABHINAYA NAGARAJANNAGARAJAN

JANANI SJANANI S

VIVEK K SHAHVIVEK K SHAH

CERAMIC TILES 4TH SEMESTER ‘A’

2009

CHARACTERISTICS•CERAMICS ARE DEFINED AS PRODUCTS MADE FROM INORGANIC MATERIALS HAVING NON METALLIC PROPERTIES.

•IT IS USED ALMOST EVERYWHERE THAT IS ON WALLS, FLOORS, CEILINGS, FIREPLACES, MURALS AND AS AN EXTERIOR CLADDING ON BUILDINGS.

•CERAMIC TILES ARE HIGHLY DURABLE

•THEY ARE ABRASION RESISTANT

•THEY ARE IMPACT RESISTANT

•THEY ARE STAIN RESISTANT TO ALMOST ALL ACIDS, ALKALIS AND ORGANIC SOLVENTS

CHARACTERISTICS OF VITRIFIED TILES

•THEY ARE HIGH QUALITY, HIGH GLOSS, SUPERIOR POLISHED SURFACES

•THEY ARE RESISTANT TO CHEMICALS, ABRASION, FIRE & STAINING, EASY TO MAINTAIN AND ENSURES HYGIENIC SURROUNDINGS.

CLASSIFICATION

CERAMIC MOSAIC TILES: COMPOSED OF PORCELAIN OR NATURAL CLAY, SIZE LESS THAN 39 cmsq

DECORATIVE WALL TILE: A GLAZED TILE WITH A THIN BODY USED FOR INTERIOR DECORATION OF RESIDENTIAL WALLS

PAVER TILE: GLAZED OR UNGLAZED PORCELAIN OR NATURAL CLAY TILE

PORCELAIN TILE: CERAMIC MOSAIC OR PAVER TILE THAT IS MADE BY DRY PRESSING

QUARRY TILE: GLAZED OR UNGLAZED OF SAME SIZE AS PAVER TILE BUT DIFFERENT METHOD OF MANUFACTURE

CERAMIC TILES 4TH SEMESTER ‘A’

2009

BRANDS OF CERAMIC TILES

THE VARIOUS BRANDS AVAILABLE IN THE MARKET ARE AS FOLLOWS

JOHNSON NITCO

BELL CERAMICS RAK CERAMICS

KAJARIA TILES ASIAN CERAMICS

EURO CERAMICS OREVA CERAMICS

TYPES OF CERAMIC TILES

WALL TILES

FLOOR TILES

•CERAMIC

•VITRIFIED

TYPES OF FINISHES

MATTE GLOSSY

ANTI-SKID RUSTIC

THICKNESS OF CERAMIC TILES VARY FROM 8mm TO 12mm.

TILE SIZES AVAILABLE ARE:100cmX100cm200cmX200cm45cmX45cm60cmX60cm10cmX5cm

METHOD OF MANUFACTURE:

RAW MATERIALS

-CLAY

-FLINT-IS A FORM OF SILICON DI OXIDE PRODUCED FROM SAND

-FELDSPAR-CONTAINING SODIUM AND POTASSIUM ALKALIES

METHOD:•PRIMARY CRUSHERS ARE USED TIO REDUCE LARGE LUMPS OF THE MATERIAL

•SCREENS ARE USED FOR SEPERATION OF PARTICULAR SIZE. THEY OPERATE IN A SLOPED POSITION AND ARE VIBRATED MECHANICALLY OR ELECTROMECHANICALLY TO IMPROVE MATERIAL FLOW.

AFTER PROCESSING OF RAW MATERIAL

•BATCHING-ACCORDING TO THE RAW MATERIALS USED, COLOURS AND SIZES, THEY ARE SEGREGATED.

•MIXING AND GRINDING- AFTER WEIGHING,IT IS PUT IN A SHELL MIXER,RIBBON MIXER OR INTENSIVE MIXER WHICH ROTATES TO MIX THE MATERIALS. SOMETIMES WATER IS ADDED WHILE MIXING. THE MIXTURE IS THEN CALLED SLURRY OR SLIP. WATER IS THEN REMOVED BY FILTER PRESSING.

•SPRAY DRYING-IF A CERTAIN AMOUNT OF WATER STILL REMAINS, THEN IT IS REMOVED USING SPRAY DRYING.

•FORMING-MOST OF THE TILES ARE FORMED BY DRY PRESSING.

•DRYING-THE TILES ARE DRIED TO REMOVE THE WATER TO PREVENT CRACKS. THERE ARE TWO TYPES OF DRYING:

INFRARED DRYING FOR THIN TILES

MICROWAVE DRYING FOR THICKER TILES

•GLAZING-THE MATERIAL IS MADE TO MELT ONTO THE TILE SURFACE DURING FIRING. GLAZE PROVIDES MOISTURE RESISTANCE AND DECORATION.

•FIRING-AFTER GLAZING THE TILE, IT MUST BE INTENSELY HEATED TO IMPART STRENGTH AND GIVE IT POROSITY.

CERAMIC TILES 4TH SEMESTER ‘A’

2009

CERAMIC TILES ARE FAIRLY EASY TO INSTALL, BUT REQUIRES A SMOOTH AND RIGID SUB-FLOOR TO SUPPORT THE INSTALLATION. CERAMIC TILES ARE NOT FLEXIBLE IN THE LEAST, SO THEY CAN CRACK IF INSTALLED OVER A ROUGH SURFACE OR THIN SUB-FLOOR.

•FIRST A DRY RUN IS DONE-LAYING DOWN THE TILES WITHOUT USING AN ADHESIVE TO SEE HOW THEY FIT. •THE TILES ARE THEN LAID ALONG A PERPENDICULAR LINE AND A SPACER IS USED BETWEEN EACH TILE IN ORDER TO MAINTAIN EQUAL SPACING OF THE TILES.• AFTER DECIDING THE PLACING OF TILES ALONG AND ACROSS THE ROOM, USING THE NOTCHED TROWEL, APPLY A 2-FOOT SQUARE AREA OF TILE ADHESIVE IN THE STARTING CORNER.• AS EACH TILE IS LAID, WORK IT INTO THE ADHESIVE. •THE SPACER IS USED TO MAKE SURE THE TILES ARE SPACED EVENLY.• A LEVEL IS USED TO MAKE SURE THE TILE FACES ARE FLUSH.• A RUBBER MALLET OR A BLOCK OF WOOD AND A HAMMER CAN BE USED TO GENTLY TAP DOWN TILES THAT ARE TOO HIGH.• ONCE THE ADHESIVE HAS SET UP, ONE CAN WALK ON THE TILES TO CUT AND INSTALL THE BORDER TILES.• THE TILE AT THE BORDER IS CUT ACCORDING TO MEASUREMENT TO FIT,• WITH A TILE CUTTER. ONCE ALL THE TILES ARE LAID AND THE ADHESIVE HAS SET,• THE GROUT  IS APPLIED WITH A RUBBER FLOAT AT A 45-DEGREE ANGLE, INTO THE SPACES. EXCESS GROUT IS REMOVED USING A SPONGE.

LAYING AND INSTALLING METHODSMATERIALS REQUIRED:•TILE ADHESIVE•GROUT•CERAMIC TILES•GROUT SEALER•TILE SPACER

TOOLS:•TILE CUTTER•CHALK LINE•TAPE MEASURE•RUBBER MALLET•TILE NIPPER•NOTCHED TROWEL•LEVEL 

PROCESS

CERAMIC TILES 4TH SEMESTER ‘A’

2009

CERAMIC TILES 4TH SEMESTER ‘A’

2009

BRAND: KAJARIA TILES

USES-USED IN KITCHENS,LIVING,BATHROOM,OUTDOORS AND COMMERCIAL.

SIZES-300mmX300mm , 450mmX450mm

FINISHES-MARBLE,MATTE,SATIN,SATIN MATTE

THICKNESS-8.2mm

VITRIFIED TILES

FINISHES-Solitaire, Elegant, Double Charged, Super White & Premium

SIZES-600mmX600mm,800mmX800mm

COSTING

COST OF CERAMIC TILES: Rs.25 TO Rs.45 PER sqft

COST OF VITRIFIED TILES: Rs.40 TO Rs.150 PER sqft

COST OF INSTALLATION Rs.8 TO Rs.15 PER sqft

OTHER COSTS INCLUDE COST OF MATERIALS LIKE SAND, CEMENT OR ADHESIVE

CERAMIC TILES 4TH SEMESTER ‘A’

2009

DIFFERENCE BETWEEN VITRIFIED AND CERAMIC TILES 

• VITRIFIED TILES ARE HOMOGENEOUS BODIES OF CLAY, WHICH HAVE BEEN FIRED AT HIGH TEMPERATURES TO ENSURE A LOW WATER ABSORPTION AS COMPARED TO CERAMIC TILES WHICH ARE MORE POROUS IN NATURE. THE CERAMIC TILES ESSENTIALLY CONSIST OF TWO MAIN PARTS VIZ. THE 'BODY' (CLAY) AND THE 'GLAZE' (SPECIAL COLOR PIGMENTS MIXED WITH CLAY ETC.)

• VITRIFIED TILES HAVE A VERY HIGH DIMENSIONAL ACCURACY. CERAMIC TILES HAVE AN INHERENT NATURE DUE TO WHICH VARIATION IN LENGTH & WIDTH (+/- 5% INTERNATIONALLY ACCEPTABLE LIMIT) GENERALLY OCCURS. THIS IS OFF-SET BY USING THE 'GROUTING' TECHNIQUE, WHEREIN A GAP OF ABOUT 5 MM IS LEFT BETWEEN THE TILES TO COVER UP SUCH DIMENSIONAL INACCURACIES THAT MAY OCCUR IN THE LOT.

• VITRIFIED TILES BEING HARDER ARE MORE ABRASION RESISTANT THAN CERAMIC TILES AND THEREFORE IDEALLY SUITED FOR FLOORING.

• THE FORMATS (SIZES) POSSIBLE IN VITRIFIED TILES ARE LARGER THAN CERAMIC TILES, WHICH AGAIN MAKES THEM IDEAL FOR FLOORING PURPOSE. 

CERAMIC TILES 4TH SEMESTER ‘A’

2009

CASE STUDY:

COFFEE DAY

BANSHANKARI(VITRIFIED TILES)

COFFEE DAY

BANSHANKARI(WALL TILES)

CERAMIQUE,KUMARA PARK

RESIDENCE