Ceramic tile

Common and Innovative Material Application

Ceramic based paint has been introduced as a product with low VOC levels, high durability and in some brands antimicrobial protection. This paint is also said to prevent molding, mildew and bacteria from growing on or beneath its surface. Small ceramic spherical beads are used as pigment extenders, considered as the fillers used in paint pigmentation. Ceramic beads are a better alternative because they are smooth and round; therefore, they pack together. It is considered as a “green” type of paint.

Ceramic Tiles turned to fashionable art. The Paiellettes tile is the new collection from Lea Ceramiche. This contemporary tile collection is available in a range of glazed colors and patterns, and single-fired finish. [[1]]

The RepTile tile by Canakkale Seramik captures the beauty of crocodile, lizard and snake skin with a smooth sleek finish. It is offered in vivid hues and soothing neutrals. [[2]]

The Florilege Ceramic Tiles by Novoceram are chic tiles that are inspired by traditional Chinese 18th century hand-painted wallpaper and romantic palette. The tile designs come in four different components: Terre, Ciel, Cage & Paon, which can all be combined. [[3]]

The ceramic wall and floor tiles by Villeroy & Boch are inspired by the cosmopolitan culture, art and architecture. They are designed to satisfy both the modern architecture and the antique timeless pieces of art and architecture. La Diva collection has a blend of Asian and European flair with great shades like the rich-berry toned, tulipe noir, pearl and gold accents. The Cherie collection embraces the French Country style in tones of ecru, beige and bright gray. The Ivoire pattern is their classic collection which has a relief pattern available in the shades of cool cream and beige. [[4]]

Connec, the new collection from Ceramica Saloni and designed by the Rockwell group, was inspired by the Japanese architect George Nakashima. This tile has a combination of ceramic and metal for a product that can be used as paving or cladding, in addition to interior surfaces. [[5]]

South Sea Pearl Ceramic Tile Mosaic is a new collection from Artistic Tiles was inspired by natural pearl lustre. The matte pearlescent glaze provides a subtle shift in color and gives luminescence and life to tiles. The Fiji Convex brick pattern provides a wave-like texture to the already fluid-like color. This design is available in Golden Sand, Oyster Ivory, Palm Green, Teak Beige, Undersea Blue and three blends. [[6]]

Ironwood effect Ceramic Tiles by Fondovalle showcases a soft grain and solid structure. This design is available in Black Burnt, Oak, White, and Walnut finishes in plain or with scrolled and floral details. They come in two dimensions: 36”x6” or 36”x8” with applications on floor or walls as accents. [[7]]

The Preziosa collection from Bardelli is a new double-fired ceramic tile collection offers six color tiles and come in a single 13”x26” size. These tiles are decorated by real gold used by jewellers and bring luxury in any space.[[8]]

The Satoriale bathtub, and the Cupola and Tuba sinks by Antonio Lupi are elegant and classic bathroom fixture styles[[9]]

These modern bathroom fixtures from Plavis Design are made of Ceramics. The sinks are unconventional in their shapes, while the toilet and the bidet also take on a more modern form. [[10]]

Physical Properties

The notable physical properties of ceramics are that they are hard and brittle, and can be easily broken if dropped due to the minute cracks, called Griffith cracks, found throughout the tiles. Ceramic are wear-resistant, as well as being a good thermal and electrical insulator. As well, they are non-magnetic and oxidation resistant.

Ceramic tiles can be produced in a large range of sizes and shapes, ranging from a few centimeters in width or length, to one meter or larger. They can also be produced in various thicknesses, from 5mm to approximately 25mm. Also, ceramic tiles can support heavy loads without deforming or bending.

Ceramics have many other properties which allow them to be used for various applications. These properties include: high temperature resistance, high electrical resistivity (although some ceramics are superconductors), broad range of thermal conductivity, high hardness (many ceramics are brittle), good chemical and corrosion resistance, low cost of raw materials and fabrication for some ceramics, and good appearance control through surface treatments, colorization, etc.

Ceramic tile is considered inert. Due to its chemical composition it does not react to anything around it, assuming it is laid properly. This makes tile practical because it will not warp or deteriorate, and is extremely durable. It is resistant to dirt, and in general any type of stain can be removed from a tile surface.

Installation

Installing a tile floor is relatively simple and does not require a large amount of prior knowledge, as most major building depots have online tutorials on how to lay tile flooring. Before starting there is a small list of materials needed, including ceramic tiles, grout, spacers, and tile adhesive.

Since tiles are not flexible, a smooth and stiff subfloor is required. First, the layout of the room needs to be determined, making sure that the borders are equal, to determine if tiles need to be cut around the perimeter. As well, there should be a dry run to ensure there are no errors before laying the tiles into the adhesive. After choosing a starting point, the tiles can be applied to a tile adhesive using spacers to confirm that they are equally spaced. Tiles may be tapped into place with a rubber mallet if they do not lie flat. Used spacers may be popped out and reused in different areas, but if they are difficult to pull out they may also be left in and covered over with grout. Once the tiles are set into place, they are to be left for a 24 hour period, after which the perimeter tiles that need to be but can be installed.

Once the tiles are set into place, they are to be wetted and covered over with grout. Wetting the tiles ensures the grout does not bond to them. Grout should be wiped off the tiles after 5 minutes, using as little water as possible, to make sure that the grout between the tiles is not diluted. After installing the grout, it should be left for a 24 hour period, after which the remaining grout residue may be washed off.

Life Cycle Cost

Life cycle costing is a broad term, encompassing initial, installation, maintenance, and disposal costs for a product. Comparing the life cycle costs for different products can expose long term monetary savings or costs that are not immediately recognized. In terms of ceramic tiles, since there are many different types and different price points, as well as different installation methods, these two factors in calculating the life cycle cost will vary.

The approximate cost for ceramic tile per square foot is $3.50, while the installation cost per square foot is also $3.50, making the total installed cost per square foot $7.00. The total approximate life cycle cost for ceramic per square foot is $16.30. Ceramic tile is has a life expectancy of 50, and therefore the total cost per year is only 33 cents. In comparison to other types of flooring, there is only one type that is more economical than ceramic, which is quarry tile. Quarry tile has an installed cost of $6.83, a life cycle cost of $16.13, a life expectancy of 50 years, and an annual cost of 32 cents. From this it is clear that ceramics are a cost effective and long-term choice for flooring and other applications.

Raw state / Composition

Ceramic tiles are created from the natural material of clay. There are typically three types of clay used to produce ceramic tiles. These three types of clay are categorized as Kaolin, Stoneware or Earthenware. The physical properties of the tiles and the temperature at which a tile is fired in the kiln, is dependent on the type of clay used.

Despite the differences that these three types of clay possess, they also share numerous similarities. All types of clay are a natural material from the ground, found commonly where there was once a flowing body of water. All clay is a composite of soil, minerals, plants and animal remains broken up by water pressure. This composition of materials is referred to as silt, which then settles into the ground underwater, and later creates the clay used for ceramic tile production. The three categories of clay are defined by how far the silt travelled downstream.

Kaolin Clay: Kaolin clay is the purest kind of clay, as it is the type of clay that has travelled least from where it is produced. The raw clay will break apart the easiest when bent, as the particles are not as worn as other types of clay may be. Kaolin clay needs to be fired at the highest temperature of the three, at up to 2550˚F. When fired, Kaolin clay becomes shiny and smooth.

Stoneware Clay: Stoneware clay has travelled relatively far from its original place of development, but does not travel as far as Earthenware. Stoneware clay must be fired between 2100˚F and 2300˚F and results in a wide range of grays and browns.

Earthenware Clay: Earthenware clay has travelled the furthest from its place of origin. This type of clay, due to its movement, has many impurities and often may contain a large amount of sand and rock. This type of clay is identified as the softest of the three. When fired, earthenware clay must reach 1700˚F to 2100˚F, resulting in a white or grey color.

Harvesting and manufacturing process

Since clay is a material formed through earth’s natural process, deposits of it are abundant and are found throughout the world. The majority of the world’s clay deposits are found near low energy wet environments, such as large lakes or marine deposits.

Most clay is mined in open cast mines and quarries, but can also be extracted from underground mines. Clay brick and tile manufacturing plants are often located near, if not alongside, a clay deposit area, as the natural process is ever replenishing and manufacturers can save on transport costs.

Ceramic tiles are formed by combining and grinding together the raw clay with sand, feldspar, quartz and water. Next, this material is heated to reduce moisture content and becomes a powdered material. The next step in the process is referred to as dust pressing, where the powdered material is placed in a press that is powered by either electrics or hydraulics. The press forces the dust into specific shapes and sizes of tile with up to 100,000 pounds of pressure per square inch. The pressed and hardened result of dust pressing is known as the bisque.

Typically after forming the bisque, the next stage of production is the glazing. The glazing of the tile gives it a finish, such as matte or high gloss. The glazing of a tile is applied by either a silk screening technique, or by a spray. Pigmentation is also applied during glazing, mixing the pigment in with the glaze. Usually the pigment is very pale, but the colour becomes much more vibrant when fired.

The last step in the production of ceramic tiles is the firing in the kiln. As previously mentioned, the product is fired to up to 2500˚F, depending on the type of clay used to form the bisque. The higher the temperature at which the tile is fired, the stronger the end result will be. Therefore, the strongest of the clays is Kaolin clay, and Earthenware clay is the weakest.

History of Ceramics

The oldest known piece of ceramic dates back to before 8000 BCE when ancient civilizations discovered ceramics as a material to create pottery. It is speculated that at approximately 3000 BCE the potter’s wheel was created, significantly advancing technology in ceramics. The ancient Greeks are generally recognized as one of the most important founders of ceramics, however there is evidence that ceramics were also greatly advanced by the Japanese, Chinese and Turkish civilizations.

History of Ceramic Tiles

Ceramics have been used as tiles since 4000 BCE by the Egyptians. Other initial users of ceramic tiles included the Assyrians, Babylonians, Islamic Empire and Tunisians. The original process of creating ceramic tiles, which is quite similar to modern day techniques, was developed in Holland in the 17th or 18th century, and the first mass production of ceramic tile was developed in Britain in the 19th century. English tile making increased rapidly during the Industrial Revolution reaching high production levels, however the success was temporary, and the use of ceramic tiles greatly diminished. The Arts and Crafts movement of the early 1900’s revived the importance of craftsmanship and through this, brought interest back to ceramic tiles. As well, the Arts and Crafts movement demonstrated innovative use of ceramic tiles in interior locations, such as walls and fireplaces. A key reason for the use of ceramic tile as an interior treatment was due to its sanitary properties, making it ideal for bathrooms and kitchens. Architects such as Frank Lloyd Wright, H.H. Richardson and the Greene brothers all began to use tiles manufactured by a company in Massachusetts. Since the early part of the 1900’s, ceramic tiles have been utilized in increasingly diverse applications, evolving to the modern day uses and technologies of ceramics.

Cultural Significance

Throughout history ceramic tiles have been used in various methods by diverse cultures all around the world. Before the birth of ceramic tiles, pottery was a widely used medium for functional, cultural and religious needs. Asians and Greeks produced a plurality of pottery objects that served specific daily functions in their lives, to objects that were pure cultural and religious emblems of their societies. Greek pottery such as amphorae pots illustrated treasured mythological legends. These hand-painted illustrations visually narrated to its viewers, sought-after characteristics of mythological figures that indicated how Grecians should live. On the other hand, other items such as a kylix pot, which was used as a drinking cup, conformed to an extremely functional use of ceramics for the same society.

As techniques and physical properties of clay continued to be explored and discovered, ancient societies began using ceramics for increasingly diverse uses than just pottery. Egyptian pyramids, Babylon and ancient Greek cities demonstrate the first use of ceramic tiles. Ceramic tiles were first used in mosaics either for decorative purposes—tiles arranged in mathematical patterns—or for symbolic purposes, with mosaics illustrating an important individual, landscape, or story that held cultural significance to that society. This was perhaps the first use of ceramics as a finishing medium used to decorate interiors, marking a transition point of ceramics being used as a functional finishing medium—that still holds cultural meaning—instead of solitary functional or decorative pottery objects.

Many European countries developed the trend of using ceramic tile as a way to decorate their interiors, and in particular, ceramic tile became a staple in countries like Spain, China and Portugal who specialized in the craft. These societies continued to design their interiors and exteriors with the use of ceramic tile as well as use the medium in dedication towards cultural, religious and historical emblems that represented their cultures.

The industrial revolution shifted the hand-made craft into a fast-producing man-made production. Ceramic tiles and their physical properties continued to evolve; new tiles of different shapes and sizes, with different colours, textures, and quality were being produced much more quickly than before and in much higher quantity. The industrial revolution increased the production of ceramic tiles—as it is did for many other products at that time—and naturally the medium became widely accessible for more people to buy and use in their own built environments. From this point on it can be argued that ceramic tile became a staple in design and decoration in interiors and exteriors around the world, as different cultures and societies adopted this material and used it in their own expressive and cultural way in their environments.

Canadian Mosaic, Multiculturalism & Design

John Murray Gibbon was the first to use the term ‘Mosaic’ to describe Canadian culture and society in his book Canadian Mosaic. This term coined by Gibbon is commonly used to describe the multiculturalism that has shaped and continues to shape Canadian society. Canadian immigration over the past one hundred years has brought in many different people from a multitude if cultures from around the world. Each cultural group has created their own mark in their surrounding Canadian society, bringing their own customs, culture and traditions from their home and integrating it into their new surrounding society. Canada is a mosaic full of many different cultures that truly shape the ‘Canadian’ society. It is this mélange of cultures that have and continue to shape how the country’s surrounding built environments are designed.

Colours, shapes, textures, and applications of ceramic tiles vary greatly within our surrounding built structures across Canada. Bright, rich colours may have been introduced by Mexicans, and intricate tile pattern design was certainly brought along by Asians and Portuguese, but to presently pinpoint the exact cultural influences for specific tile colours, textures or designs is an ambiguous task; throughout time one influence has influenced another and as a result the influences behind the varying design of ceramic tile are themselves intertwined in their own cultural mosaic. But what can be more culturally specified is the common use of tiles in specific environments that exist in Canadian society.

The tradition of representing one’s cultural and religious beliefs in ceramic tiles has carried through from the origins of mosaic to the present day. Religious structures still use mosaics as finishing layers within their interiors and exteriors, in addition to using mosaics to visually represent a religious figure, symbol, or story. For example, many Christian or Catholic churches use mosaics to illustrate biblical stories or to present a main biblical figure. The application of these mosaics holds two functions: typically the mosaics act as the interior finish because they are applied directly to the interior wall, while serving to a second function as a symbolic and religious representation for its users.

Interior tile finishes in various ethnic restaurants also represent different cultural design traditions, visually demonstrating the many cultural and design influences from around the world that exist within this multicultural nation. An example of the latter is the tile pattern influences from Greece brought by Greek immigrants. Greek restaurants on the Danforth in the city of Toronto commonly use ceramic tile in their interiors. The tiles are typically used in flooring and in wall finishes. What is particular about these tile applications is that they include the classic ancient Greek geometric pattern either in a mosaic application or hand-painted onto larger tiles. Many Italian restaurants also use ceramic tiles as flooring that echo the rustic flooring in Italy. Some restaurants also use ceramic tiles as a mosaic wall finish, illustrating a Tuscan landscape or a jug of wine and grapes representing customs and traditions of the Italian culture.

Ceramic tile use in residential spaces within Canada is also emblematic of different culture tastes and applications. For example many Portuguese structures in Portugal are covered on the exterior with intricately design ceramic tile. In fact, Lisbon has a museum dedicated to t he history of their ceramic tiles. Many Portuguese immigrants have integrated this design element into their own homes creating new trends for residential tile design and application. In Toronto, some Portuguese homeowners have installed Portuguese-inspired tiles on the exterior facade of their houses, adding an element of design to their exterior and echoing and valuing Portuguese tradition and design. Some interiors are also filled with ceramic tiles that echo many other cultures. Different types of tile are used as wall finishes, kitchen backsplashes, feature walls and even framing fireplaces. What makes each of these applications unique are how the homeowners and designers are installing the tiles and what they are using. Again it is at this point where it becomes difficult to pinpoint direct influences of what tile design or tile application is specific to Italy or Morocco, etc, because tile designs and trends have now been shared among all cultures everywhere, becoming part of each culture and no longer belonging to just one.

A final example of how ceramic tile is culturally significant to Canadian society is the intentional way-finding use of tiles in Toronto’s subway stations. Toronto’s subway stations are covered with ceramic tiles. Each station is finished with one main tile colour and design and making each station visually distinguishable from each other. At the time of heavy immigration in the 1950s, many immigrants who came to Canada were not familiar with the English language. The Toronto Transit Commission (TTC) was a common mode for transportation for Torontonians and new immigrants because of its accessibility and cheap cost. Therefore the interior design of each subway station was no coincidence. Each station is unique in tile colour and design as an intentional way to provide a visual way-finding system for immigrants, who would recognize their home or work station not by the name of the station but by the distinctive interior tile installation.

How, where, why and what type of ceramic tile used in Canadian spaces is completely dependent on the varying tastes, desires, cultures, religions and influences of the many cultural groups that make up Canadian society. These countless influences continuously shape the cultural significance that interior materials, like ceramic tile, have on Canadian society.

The Valued Characteristics of Ceramic Tiles

Ceramic tile has evidently been a medium that has been used throughout history and presently all over the world in designed environments. The question becomes why there is such a high demand for this product. Ceramic tile is an accessible and trusted material for its physical properties that are advantageous for the functions they serve in built environments and for the environmental values designers aim to apply in their designs.

Accessibility: Accessibility of materials is a common factor in interior design for the consumer and for the designer, entailing the availability of a material as well as the cost. Tile is a completely natural material that is easy to produce at high quantity. The industrial revolution made the production of tile increase greatly naturally making it a product that became widely accessible to many people around the world. With high quantity production came lower price marks for tiles. Therefore depending on the type of tile, the design, and demanded quantity, ceramic tiles can be affordable for the consumer and thus have accommodated themselves to the varying design demands of consumers and designers alike. This accessibility allows different Canadian individuals to express their interiors according to their customs, needs, and desires. But the question of accessibility is not enough to answer the whole question of why Canadians choose ceramic tiles as a medium they want to have in their homes and public environments. It is here that it is important to look at the physical properties of ceramic tile.

Reliability: An underscoring reason in why ceramic tiles are used so widely in our environments is because the material itself is dependable. Consumers and designers alike trust the many advantageous physical properties ceramic tiles hold. Ceramic tiles are durable, impermeable, and easy-to-clean, offered in many shapes, sizes, colours and textures that are aesthetically pleasing to many. These functional and practical properties serve to the different uses within out built environments and ceramic tile is an infinite medium. Because of all of these qualities, ceramic tile can be considered a staple material in the world of interior design.

Environmental Qualities/Factors/Considerations: As a natural high quality product using only earth or clay, water and fire, ceramic tiles are considerably eco-friendly, as they do not consume or destroy large renewable natural resources and if recycled they do not leave a large ecological footprint. Although the removable of tiles is tedious, they can be recycled, as new clay can be created out of already kiln-fired objects. Ceramic tiles offer a more cradle-to-cradle solution, enabling consumers and designers to create more sustainable spaces. As an environmentally conscious nation and environmentally conscious field of design, Canadians and designers can truly rely on this eco-friendly medium.

Ceramic Tile Influence

Ceramic tiles have proven to be functional, practical, aesthetically pleasing and therefore have become a trust-worthy and reliable product in the interior design market. As a result it is an accessible material of high demand evident by the many ceramic tile manufacturers and companies that offer a wide selection of ceramic tile products. In constant attempts to provide sustainable options in design, tile manufacturers have continued to explore various tile solutions that can substitute other materials that cause more pollution or take away from more natural resources in the world. For example, Olympia Tile—a famous and large tile manufacturing company across Canada—has a ceramic tile product that resembles the look of hardwood flooring. This tile finish acts an alternative to flooring mediums in a residential or commercial space that may desire the look of hardwood flooring.

The popularity and cultural importance of ceramic tiles has also led to more popular interior design trends. The production of literary design resources such as TILE Magazine, a resource dedicated to tile in design, explores ceramic tile trends in both residential and commercial spaces.

The important culture of ceramics is also felt in Toronto’s Gardiner Museum, a jewel box completely dedicated to ceramics. While its focus is primarily showcasing pottery, the museum still demonstrates and attests to the cultural significance that the treasured medium has on Canadian society in addition to other international societies.

Environmental Impact

Ecological Footprint & VOC's

Due to the fact that some of the earliest mosaics and structures made from ceramic tiles still exist and are currently in good condition demonstrates how durable ceramic tile can be if cared for properly. High traffic areas such as lobbies that have ceramic tile flooring can last the entire lifetime of a building. The materials needed to produce ceramic tiles are easily obtainable, as different types of clay are found everywhere in the world. Ceramic tiles can also be can be made from local materials which can create a cultural sense of aesthetics. All the materials used to manufacture ceramic tiles come from natural resources. China Clay (Kaolin) is a mineral mined as Kaolinite Ore in many parts of the world, usually by high water pressure techniques. The vast majority of it is used in the paper industry while the remainder of it is mostly used in the manufacturing of ceramics. Ball Clay is used as a substitute for China clay or an additive to it and is used to bond the other tile components together. Feldspar is one of the Earth’s most common minerals consisting of aluminum and silica and is used to lower the melting point of other materials in the ceramic tile process. As well, sand is used as a filler and it also stops shrinkage and cracking. Also, quartz is used to give the tiles a hardness property and also stops deformation during the firing process. Talc is also used as a filler. Choosing ceramic tile is an environmentally sound choice since it is produced from natural clays. Ceramic tile is also an economical option because it can withstand society’s demand and the Earth’s ecological capacity to regenerate it.

Ceramic tiles do not emit volatile organic compounds (VOCs) because there are no chemical reactions or special chemicals needed to produce tiles, unless a producer experiments with certain chemicals in the glaze without having concern for the indoor air quality. Ceramic tile can also be laid with Portland-cement-based grout, which does not give off any vapors and it requires almost no maintenance at all. Low-VOC sealants can also be used on ceramic tile if needed. Toxicity is not a major concern in the manufacturing of ceramic tiles.

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Recycling & Biodegradability Options

Ceramic tiles can also be made out of recycled materials such as ground glass, automobile windshields, and old fluorescent light bulbs. Used ceramic tiles can be deposited at a recycling point, or a building material recycling specialist. From there they can be transported to a ceramic tile manufacturer. Some tile manufacturers have used recycled glass in their ceramic products as a glaze. In the case of the Terra Green Company, the most visible manufacturer of recycled glass ceramic tiles, the individual tiles are made of 55% recycled postindustrial glass. Glass is then saved from the landfill that it would occupy otherwise. There does not appear to be any ceramic manufacturers recycling used tiles however many manufacturers do recycle their own reject tiles.

The production of tiles is very energy-intensive. In order to make tile out of raw materials, the clays must be fired at least once. Due to the large quantity of decorative ceramic tile being glazed, it requires another firing. A typical firing for clay-based tiles is about 2200oF. Non-renewable energy from fossil fuels is typically used in the production. Ceramic tiles cannot be used again in the same capacity, meaning they cannot be melted down and reused as a tile again, but they can be down cycled. Down cycling is used to prevent wasting potentially useful materials, reduce consumption of fresh raw materials, reduce energy usage, air pollution and water pollution, and lower greenhouse gas emissions.

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Student contributions

• Ann Ahn, Valerie Cardozo, Madeline Filmore, Spencer Jeffries, Olha Haliuk, Adriana Pietropaolo & Nadia Pulez, 2010, Ryerson University