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All Porcelains Are Not Created
Equal
By Estelle Davis
“Porcelain stoneware” is used to designate the technical
characteristics of the product, which is an extremely dense fully
vitrified ceramic material. There are no chromatic or compositional
variations throughout the body mass. This product enters a crystalline
phase during firing, which affects the vitrification of the material.
“Vitrification” indicates the process of compaction obtained by
melting and cooling of the body mass during production. Raw materials
used in the production of porcelain stoneware are classified into the
following groups; ultra pure clay, feldspar, quartz, kaolin.
The key and most important product in the composition of porcelain
stoneware is “feldspar”. This material is essentially responsible
for the predominant vitreous and compact nature of the final product.
All raw materials must be accurately controlled. However the
percentage of feldspar used in the product directly relates to the
absorption factor, the vitrification of this product, its ability to
resist staining and ultimately the ease of maintenance. Although
visually, various porcelains may look almost identical, it is the
technical characteristics that determine if it is truly equal.
The technical characteristics of porcelain can be determined by
reviewing the independent test results of a range of laboratory tests.
Summarized in brief are the test type, the test methods, as well as
the minimum requirements which would allow the end user to compare the
technical characteristics of the various porcelain products, for an
informed and valued decision. Although, for the layman, aesthetically,
various products may appear to be identical, in fact, when compared in
this fashion, they are not.
The most expensive component in porcelain production is feldspar and
this production cost is transferred somewhat into the end selling
price. It is this key and most apparent point that must be examined
when a selection is being finalized. Should the end selling price be
uncharacteristically low, then there is a strong possibility that the
actual production costs are less expensive. The percentage of feldspar
used in the composition is reduced. This will undoubtedly result ina
more porous, less dense product.
Another key area to be examined by all parties involved in the final
product selection should be the manufacturers recommended maintenance
requirements for both the initial stages and the daily and weekly
programs.
Maintenance of any flooring material is an area that in many instances
is overlooked. However, this is an ongoing cost factor that should be
seriously considered in the final product selection stages.
Any flooring material will require a maintenance program, but the key
to the issue that will result in long term ongoing costs is the
recommendation by the actual manufacturer on whether or not to seal
the product to obtain full vitrification or render the product
completely impervious.
The initial cost savings per square foot for material may in fact
translate into a product which although aesthetically appears equal,
will undoubtedly be much more difficult to maintain. The initial clean
will be more difficult and the costs to maintain this product
throughout the life of the installation will be a regular ongoing
concern to the end user.
It is vital in the selection and specification of porcelain material
that full independent comprehensive test reports be
submitted/requested along with the product. By stressing the high
calibre of performance substantiated by independent test reports,
costs should not be a major factor in the final stages. As we stated
“All porcelains are not created equal...”.
Estelle Davis is General Manager of Dal Tile Canada
Inc. and has over twenty five years experience in the ceramic industry
throughout Canada and the United States. Estelle can be reached at
905.850.4390 or 800.668.0988.
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