uses of tiles (1)

7/31/2019 Uses of Tiles (1)

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Tiles are one of the most versatile building materials. Theyare just not used for walls and flooring we can use them fordecoration protection or less common applications. Sincethey are light and easy to install, anyone can work withtiles for a wide range of improvements.

A tile is a manufactured piece of hard-wearing materialsuch as ceramic, stone, metal, or even glass.

Tiles are generally used for covering roofs, floors, walls,showers, or other objects such as tabletops.

Alternatively, tile can sometimes refer to similar units madefrom lightweight materials such as perlite, wood,and mineral wool, typically used for wall and ceilingapplications.

Less precisely, the modern term can refer to any sort ofconstruction tile or similar object, such as rectangularcounters used in playing games


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Types of Tiles

The word ceramic comes from thegreek word keramos meaning pottery,it is related to an old sanskrit rootmeaning to burn but was primarily

used to mean burnt stuff. Ceramic tiles are hard and brittle in

nature. They are also known to be heatand corrosion resistant in the long run.

These tiles come in various finishes like

the anti skid and mat finish, which areused on steps and in bathrooms. Floortiles come in squares and wall tiles aremostly rectangular.


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It is created by the vitrificationprocess.

It is processed in ways that it has verylow porosity (and water absorption)making it stain-resistant and strong.

Vitrified tile is an alternative to marbleand granite flooring. They have farsuperior properties compared tomarble or natural granite because

being a manufactured product theirquality is controlled whereas innaturally occurring marble and granitegood quality is just a coincidence.

.Vitrified tiles possess much better mechanicalstrength, scratch resistance, resistance to acids,

alkalis and chemicals, resistance to staining etccompared to marble or natural granite.Vitrified tiles may be laid in a matter of hours and put

to use after 48 hours.The tile is known for glazed look and a classic shineand is mostly being used in offices and commercial

buildings


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This type of flooring involvesembedding small pieces of colored

glass, stone, or ceramic tile calledtessera in a background materialsuch as plaster or mortar. Theresulting finish is unique and avariety of designs can be created.

Most conventional apartments usegrey or white mosaic. These arerelatively inexpensive. Moreaffluent variety of mosaic is alsoavailable in the market for thedeserving people.

These tiles have multicolouredblock in them with a glass finishthat makes them shine and aremostly used in kitchens,swimming pools, wash rooms and

pooja rooms.


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Polyvinyl chloride (P.V.C.) tiles are a

commonly used floor finish. The tiles are made of a composite of

PVC and fibre, producing a thin andfairly hard tile.

The surface wears, in time causing

difficulty in cleaning, then loss of thecolored pattern layer.

Finally a very smooth floor is requiredto lay them on, otherwise theygradually become cut by the foot

pressure above and the shallow edgesbelow.

The main advantages of PVC tiles arelow cost, ease of replacing individualtiles, and the fact that the tiles can be

laid with only brief periods available.


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Rubber floor tiles are most

commonly used in high-traffic areaswhere easy cleanup is a priority.

For this reason, they are consideredthe ideal choice for a basement,workshop, garges or even a home

gym. Some rubber floor tiles have raised

surfaces to prevent slipping, andthese are ideal for areas wherewater is a factor, such as a mud

room or patio. Like other rubber products, rubber

floor tiles come with a distinct odorthat diminishes with time, whichmay make them a concern for those

who are sensitive to the scent.


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USES:

Here are some places aroundthe home that can benefit

from tile applications:

1. Counter2. Bathroom

3. Backsplash

4. Flooring5. Wall Accents

6. Exteriors


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Ceramic tile is among the most common materials forkitchen countertops. Because it's hard and water-resistant, itholds up extremely well to the moist and often humidenvironment of the kitchen. If you're busy, you'll also like itslow-maintenance nature; a quick wipe once in a while isusually all it needs


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Mostly used on floor

They are commonly used in

walls


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The backsplash tiles protects the walls against spillscoming from the sink and counter. Almost all

backsplashes are made of tile because of its naturalwater resistance. Some people prefer stone or marble,but these are expensive materials. We can use the sametile design as your countertop, or go for a contrastingcolour for a stronger effect.


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Tile is one of the

cheapest flooringoptions, especiallycompared to popularmaterials such ashardwood and marble.

Most tiles can withstandheavy use in living roomsand the heat andmoisture of bathrooms.Best of all, it's easy toinstall-you don't needmuch prior experience tolay a floor tile on yourown.


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Small decorative tiles make great accents for walls,

counters, and flooring. They usually come in stronger,deeper colours and feature interesting patterns, often tocomplement the colour of bigger tiles. Use them to dressup large walls or to create designs on your tile floor.


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Some tiles can actually

be used on the exteriorwalls of your home.These are usuallydecorative ones made tolook like natural

materials, such as woodand stone. They makegreat alternatives toexterior painting, sincethey don't fade and can

withstand most outdoorelements. Since youwon't be stepping onthem, you can uselarger, lighter tiles tomake installation easier


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Fixing of ceramic tiles:

Mix up the tile adhesive. Tile adhesive has a limited pot life,

about 20 minutes, so do not mix up more than realisticallybe able to use in time available.

Lay first tile in the corner furthest from the door. In orderaccurately to position the tile, dry-lay a line of tiles from thecentre line, and then draw a line at right angles to the

centre line along the far edge of the whole tile at rightangles to your guideline. Providing this line is parallel to thecentre line the last tile you dry-laid is first tile.

Spread the adhesive over an area of approx. 1sq m (1sq yd)at a time.

Using the recommended side of a notched spreader ortrowel, apply the adhesive to the correct depth, normallyapproximately 3mm (in).

Depending on the adhesive being used, it may be necessaryto butter the back of the tile with adhesive as well.


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Press the tile into position with a slight twisting motion. It isimportant to bed the tile into the adhesive without any airgaps. For neat and even joints, usually 6-12mm (-in.), use

plastic spaces between the tiles. Continue laying the tiles in the first marked square. If any

adhesive gets on the surface of a tile clean it off immediatelywith a damp cloth; ensure too that the joints are adhesive-free.

When the first grid box has been laid, apply adhesive to thesecond and continue laying tiles along the far wall. Thencomplete the second row of squares and continue laying thetiles in rows of boxes, working towards the door. Allow the tileadhesive to dry thoroughly before walking on the tiles.Conventional adhesives usually need at least 24 hours althoughfast-setting adhesives can take only a few hours.


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It will probably be necessary to cut tiles aroundthe edges of the room to fit; if you lay the tileson the diagonal, you will need to cut at least one

in every two tiles. Ceramic tiles can be cut usinga tile-cutting jig.

Butter the back of the cut tile and press intoposition. Continue until all the border tiles have

been laid, leaving the four corners until last inorder to cut them accuratelyTo determine whereto cut a border tile:

Place a whole tile over the last laid whole tile.

To allow for a grout, place a tile on its side

between this tile and the wall and place anothertile up against it.

Mark the middle tile with a soft pencil where thetile above it ends.

Place the tile in the jig and cut along the marked

line.


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Grouting Ceramic Tile

When all the tiles have been laid and the adhesive is dry, fillthe tile joints with a tile grout suitable for floors.Conventional grout is a powder mixed with water accordingto the manufacturers instructions. It is available in colorsranging from off-white to dark grey.

For food-preparation areas an epoxy grout is a good ideabecause it is extremely hard and easily cleaned. Epoxygrout consists of two components that are mixed together,and then a powder filler is added to bulk it out.

Pour the grout onto the surface and spread it into the jointswith the aid of a rubber squeegee, working on small areasat a time.

After 15 minutes, clean any excess grout off the surfacewith a damp cloth.

Once the grout has hardened sufficiently, polish the tileswith a clean, dry cloth.


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Fixing of vitrified tiles Prepare base mortar with cement and sand in the ratio of

1:4.

The total mortar thickness should not be more than 25mm.

Set the levels for the floor i.e. dead level or slope asspecified.

Prepare cement slurry with cement and water to form a

thick paste and spread it on the leveled base mortar. Wet the rear side of the tile with water. (Complete

immersion of tile is not necessary)

If tiles are square or rectangular in shape, set the rightangles for the area and place the first tile along the right

angle line on base mortar. Tab gently with a rubber malletto get perfect level.

After laying, immediately clean the surface of the tiles withclean, wet sponge. Ensure that the base mortar cement,which squeezes through joints, does not settle on the tile.


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Also make sure that the water used isnot hard or brackish.

Do not use the area laid for 48 hours.

Fill in the joints with pointing materiali.e. mixture of white cement anddesired colour pigment. For higherquality of finishes, you could use, ifrequired, a polymer based cementitous

tiling joint filler. To get the desiredcolour / shade, mix the same withwater to form a smooth paste, whichshould be applied to the joints,preferably with the use of a rubbersqueezer. Do not apply the pointingmaterial all over the surface.

Allow the pointing material to set for 15minutes. And clean the surface of thetile with clean wet sponge, in order toremove the excess pigment on the tilesurface.


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The polyvinyl chloride resins are mixed with calciumcarbonate, plasticizers, and pigments in a large industrial

mixer. The mixture is heated to melting and consolidated. The

friction from the mixing blades produces a compound withthe consistency of bread dough. The dough-like substanceis put through calendar rollers and the material is squeezed

into sheets. The sheets are embossed while still in rolls. Once

decorated, the sheet is then cut into individual tiles with adie cutting machine, resembling multiple cookie cutters.

The tile squares (12 x 12 in or 30.48 x 30.48 cm) are

cooled and put into a box if they are dry sheets (withoutpressure-sensitive glue on the back). If they are to receiveglue for affixing to the floor, a roll-coater carrying organicresins deposits the glue on the tile backing. A paper coverthat protects the glue is put over backing. The tiles are

boxed (in boxes of 10 or 12) and ready for shipment.


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The ceramic tile manufacturing process consists of a seriesof successive stages, which can be summarised as follows:

Raw materials preparation

Pressing and drying of the green body

Firing, with or without glazing

Additional treatments

Sorting and packing

Raw materials preparation

The ceramic process starts by selecting the raw materialsrequired for the body composition, which are mainly clays,feldspars, sands, carbonates.

In the traditional ceramic industry, the raw materials aregenerally used as-mined or after some

Minor treatment. As natural raw materials are involved,preliminary homogenization is required in most cases toensure consistent characteristics.


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Dry or wet milling

After a first mixing of the body components, the mixture is usuallydry milled (hammer or pendulum mills) or wet milled (continuous

or batch ball mills). The resulting milled material exhibits different characteristics

depending on whether dry or wet milling is used. In dry milling,fragmentation occurs and particle aggregates and agglomeratesremain, with a larger particle size (there are particles larger than300 microns) than by the wet method (all particles are smallerthan 200 microns).

In wet milling, the raw materials can be wholly or partially fed intothe ball mills, which is normally the case, or they can be directlydispersed.

Part of the water contained in the resulting suspension (slip) is

removed by spray drying to obtain a product with the requiredmoisture for each process stage. Spray drying is the most widelyimplemented drying method in tile manufacture.

In this drying process, the fine drops of sprayed suspension comeinto contact with hot air to yield a solid with a low water content.


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The moisture content of the body slip usually ranges from0.0-0.45 kg water/kg dry solid. The spray-drying processreduces the water content to 0.05-0.07 kg water/kg drysolid.

Spray drying takes place in the following steps.

Pumping and spraying the slip.

Hot gas generation and feed.

Drying by contact of hot gas-slip drops.

Separation of spray dried powder from the gases.

Mixing

In this body preparation stage, the water and raw materialsmaking up the body composition are

closely mixed to a consistent paste that is readily mouldableby extrusion.


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Dry pressing

Dry pressing (at 5-7% moisture content) with hydraulicpresses is the most common tile forming method.

Forming takes place by mechanically compressing the pastein the die and is one of the most cost-efficient formingmethods for making ceramic ware with a regular geometry.

In pressing, the oil-hydraulic press system drives the ramsinto the powder bed in the die

Extrusion

Tile forming by extrusion processes basically consists ofputting the plastic body through a die

that produces a constant tile cross section.

The equipment involved is made up of three main parts: a

driving system, the die and the cutter. The most common driving system is an auger.


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Drying of the green ceramic bodies

After forming, the tile body is dried to reduce the moisture content(0.2-0.5 %) to appropriately low levels for the firing and eventualglazing stages.

In the dryers that are commonly used in the ceramic industry,heat is transferred mainly by convection from hot gases to the tilesurface, and also slightly by radiation from these gases and fromthe dryer walls to the tile surface. Therefore, during the drying ofceramic bodies, a simultaneous and consecutive displacement of

the water takes place through the wet solid and the gas.

The air used must be sufficiently dry and hot, because it not onlyserves to remove the water from the solid but also to provideenergy in the form of heat to evaporate the water.

At present, the bodies are dried in vertical or horizontal dryers.

After shaping, the bodies are placed in the dryer where they face ahot gas countercurrent. The hot gases come from an airnaturalgas burner or from the kiln cooling stack.

The main heat transfer mechanism between the air and the bodiesis convection.

There are two type of dryer vertical and horizontal..


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Firing, with or without glazing

Unglazed products are fired after the drying stage. Similarly, inthe case of glazed twice-fire products, the green bodies are

fired after drying.

Glazing

Glazing involves applying one or more coats of glaze with atotal thickness of 75-500 microns onto the tile proper surfaceby different methods

Glazing is done to provide the fired product with a series oftechnical and esthetical properties such as impermeability,cleanability, gloss, colour, surface texture, and chemical andmechanical resistance.

The nature of the resulting glaze coating is essentially vitreous,although in many cases the glaze structure contains crystallineelements.


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Glazes and frits

The glaze, just like the ceramic body, is made up of a series ofinorganic raw materials. The major glaze component is silica(glass former), as well as other elements that act as fluxes(alkalis, alkaline earths, boron, zinc, etc.), opacifierszirconium, titanium, etc.), and as colouring agents (iron,chromium, cobalt, manganese, etc.).

A wide variety of glazes are formulated depending on the typeof product, firing temperature, and the desired effects andproperties of the finished product.

In other ceramic processes (porcelain artware, sanitaryware), glazes are formulated that only contain crystalline,natural or synthetic raw materials, which contribute thenecessary oxides.

However, in ceramic floor and wall tile manufacture, rawmaterials of a glassy nature (frits) are used.

These are prepared from the same crystalline materials thathave previously undergone heat treatment at hightemperature.


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Frits: Nature, advantages, composition and manufacture.

Frits are vitreous compounds, insoluble in water, made by meltingat high temperature (1500C) followed by fast cooling of the rawmaterials mixture.

Most of the glaze compositions used in tile manufacture have alarger or smaller fritted part, which can consist of a single frit orblend of different types of frits.

For a given chemical composition using frits has certainadvantages compared to using unfritted raw materials, such as:

Insolubility of certain chemical elements.

Lower toxicity; owing to its size and structure, the frit tends toform less ambient dust than the original raw materials, thusreducing the hazard associated with raw materials toxicity.

Wider glaze working temperature range, as they have no defined

melting points. The purpose of the frit production process, usually known as

fritting, is to obtain a vitreous material that is insoluble in waterby melting and subsequent cooling of the mixture of different

materials.


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Glazes: Preparation and application. Decoration

In the glaze preparation process, the frit and additives areusually ground in alumina ball mills until a preset reject isobtained.

The conditions of the aqueous suspension are then adjusted.

Ceramic tile glazing is done continuously.

Firing

Firing is one of the most important tile manufacturing process

stages as most tile characteristics depend on it. These includemechanical strength, dimensional stability, chemicalresistance, cleanability, fire resistance, etc.

The main variables to be considered in the firing stage are thethermal cycle (temperature-time, and kiln atmosphere, which

must be adapted to each composition and manufacturingtechnology, according to the ceramic product to be made.

In the firing operation, the tiles are subjected to a thermalcycle during which a series of reactions take place in the piece,generating changes in the microstructure and providing the

desired final properties.


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uses of tiles (1)

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