There is a tile for every use and a use for every tile

Porcelain tile is one of the fastest growing categories in the ceramic tile industry, especially in North America. It has enjoyed such a meteoric rise in popularity that many designers and architects are narrowing their choices to porcelain tile for every installation. And, although there are many varieties of porcelain tile on the market, which all have different properties, it is often wrongly assumed that all porcelain tiles are identical.

The full range of porcelain tiles is somewhat confusing, but a clear understanding of the different terms that identify each composition will not only simplify the selection process, it will ensure that the tile chosen is appropriate for the job. Tracking the development of porcelain tile production is the easiest way to identify each type and understand where, when and how it should be incorporated into the overall ceramic tile design.

There are some general concepts that apply to all porcelain tiles. A standard description would have the following characteristics:

1. A dense impervious body;
   (Not capable of being passed through, damaged, or disturbed)
2. Usually produced by the dust pressed method;
   (An almost dry mixture blend of fine-grain clays and other minerals pressed into a mold at extremely high pressures).
3. The mold is fired in extreme heat;
   (Very high temperatures 2000 to 2500° F).
4. Having extremely low porosity;
   (The ratio of the volume of all the pores in a material to the volume of the whole).

What is commonly referred to as porcelain tile today started in the early 1980’s. The tile industry referred to one product only as porcelain tile, since only ‘UNGLAZED’ porcelain was in production in the early years (Generally with a natural surface).

Series: Buxy, Color: Caramel, Manufacturer: Cotto D'Este

The original terminology required no additional defining adjectives other than SALT & PEPPER, to describe the multi colored or granite-like look or SOLID describing any single color tile. The term porcelain was simple, easily understood, and the original product quickly established its value in commercial specification. Porcelain, in that early, unglazed form, was conceived and developed to satisfy the rigors of demanding environments: exterior applications, heavy pedestrian and vehicular trafficked floors, areas subjected to excessive water penetration or temperature fluctuations, and places where damage from aggressive chemicals or acids were likely. In order to create the unique inner microstructure of porcelain, high quality raw materials and specialized production techniques are required. The pore structure is critical to achieving; good color development, mechanical strength, and stain and frost resistance.

The design community particularly appreciated the extremely hard, unglazed tile’s natural deep abrasion and slip resistance.

To achieve specific technical objectives, initial porcelain production suffered from a lack of aesthetics. The unglazed surface also required a higher level of maintenance and its limited surface patterning offered little soil hiding ability. Polishing of the unglazed tile was soon adopted into the process as the resulting high gloss finish added sophisticated textures to an otherwise limited design selection. Unfortunately, surface polishing opens the closed pore structure of the porcelain body and polished porcelains are more susceptible to staining because dirt gets trapped in the opened surface pores.

Sealants or other pre-surface treatments can prevent this problem as long as routine re-application of the protective treatment is maintained.

Over the past twenty years, many decorating techniques have been developed to add depth, pattern, texture and natural variation to unglazed porcelain tile. All of these treatments are incorporated into the homogeneous body, maintaining the commercial benefits of each tile while improving its visual impact and increasing soil resistance.

During the past ten years, worldwide demand for porcelain tile, commonly referred to as porcelanic gres, has soared. Italy remains the leader in porcelain, with a production increase from 95 million square meters per year in 1996 to over 250 million square meters per year by 2000. In fact, porcelanic gres now accounts for 48% of the floor tile produced and 35% of Italy's total tile production.