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.

TERRAZZO, TILE AND STONE - FOR A LIFETIME OF BEAUTY?
By Jim Mannella

The other morning, the phone rang and when I answered, I recognized the voice as the mother of one of the players on my son’s baseball team.

"Good morning, Mr. Mannella"

I must be getting old, as everybody is starting to call me Mr. Mannella.

"Good morning"I replied.

I started to get ideas of a father-son baseball game being organized, and that must be the reason that she was calling. "You are in tile and marble, aren"t you?"she said.

Uh-oh, I thought, I'm in trouble now, thinking that once again, someone was calling for a helping hand, for only a few hours, to install some tile somewhere in their house. Don'these people know I'm only an estimator!

"Well", I explained, "our company does tile and marble installations, with the tile setters who work for the company."

"I've got a problem in my bathroom", she explained. "All the tiles on the floor are breaking and coming loose, and I was wondering if you knew how to stop this from occurring."

She went on to explain that she had received some expert advice from a large home renovation centre, who sold her the tile, adhesive and the grout, and a friend of a friend installed it for her, after assuring her that he had done it before, and there was nothing to it.

"Is it normal to have the tiles butt up against each other, because we can't get the grout in the joints?" she asked. "Are you sure it's a floor tile you have?"I asked. "Is there a difference between tile for walls and floors? was her answer. "Is the floor installed on two layers of plywood?" I asked. "The installer told us that the ½" layer of plywood sheathing was good enough"she replied. "Is there enough adhesive on the floor to properly bond to the back of the tile? I enquired. "Well, when I take up a loose tile, there doesn't seem to be hardly any glue bonded to the back of the tile." "Did he use a trowel with a large notch for the adhesive?" "Do you have to use a notched trowel?

It was at this point, when I realized that this floor had no hope, and it's chances for long term survival were next to nothing.

I'm afraid that the only thing that you can do is to remove this tile floor, and start over doing it properly. "was my final conclusion to her story.

As much as I feel a certain sympathy for people in such predicaments, it kind of confirms the old adage that you get what you pay for in life. What should have been an installation that should last a lifetime, was really an installation that would be a continuous source of problems. Just because we install products thats should give the owner a "Lifetime of Beauty" as our motto states, trouble free installations are not necessarily guaranteed in our industry.

Trouble free, lifelong installations are the result of several factors. First, a thorough analysis of the area involved is required in order to help you decide what type of installation is required. Are we installing tile in a residential kitchen, or in a commercial kitchen. These two installations are at opposite ends on the guide for floor tile installation, and require different tiles, different substrates, and different setting and grouting materials. Using a residential method of installation for the commercial kitchen project will surely result in premature failure. The “2000 Specification Guide 09300 - Tile Installation Manual” is a tremendous source for the owner and architect in helping them decide the best method of installation for their project.

The second important element for a trouble free installation is the use of a knowledgeable and experienced contractor for your project. An experienced contractor brings with him the wealth gained from previous projects, and often this experience will prevent many problems you may have with installers who have little or no experience. I am often amazed as to the myriad of bidders who bid and are allowed to bid on projects which are obviously not close to their expertise.

The experienced installer can be used as a consultant for the project. He will recognize if you are using the proper tile for your installation, can recommend a proper installation method, can guide you as to required surface preparation, the proper use of control joints, and even guide you as to the proper use of periodic maintenance procedures once the job is finished. Owners and architects are encouraged to consult with the TTMAC as a reference for reputable and experienced installers. The staff will gladly steer you in the right direction, and suggest several different contractors in your area who are qualified for certain types of work.

Jim Mannella is President of National Ceramic + Granite Limited of Montreal. He is the immediate Past President of the Terrazzo, Tile and Marble Association of Canada, and has been a Director of the Association for many years.

TILE AND STONE SEALERS: FACTS YOU SHOULD KNOW!
By Bill Tran

The primary function of a tile or stone sealer is to render a porous tile or stone installation more stain resistant. In providing greater stain resistance, a secondary benefit will be to reduce ongoing maintenance.

Sealers are designated as penetrating (impregnator) or coating-type, based on whether they are designed to penetrate below surfaces or form a barrier on the surface. Typically, penetrating (impregnator) type sealers are highly viscous and designed to penetrate the porous tile or stone, leaving little or no surface residue. Penetrating sealers usually leave no surface sheen and do not change the natural look of the tile or stone being sealed. Penetrating (impregnator) type sealers may be either solvent or water-based. Solvent based sealers normally have more of a tendency to darken the tile or stone than water based penetrating sealers.

Penetrating (impregnator) type sealers are usually designed to stand alone without the need for a topical finish to protect the sealer. This is because the sealer penetrates and does not lay on the surface, thus it is not directly affected by surface wear.

Coating type sealers will normally penetrate the porous surface to some degree (at least on the initial application), but are usually designed to form a coating or film on the surface of the tile or stone. Coating type sealers may vary from a very low sheen to a very high sheen.

Although some coating type sealers are designed to stand alone and provide reasonable wear capabilities, most are designed to be used only with a wax type finish applied after the sealer is applied. The reason for this is that most coating sealers are hard to repair after direct wear and abuse occurs whereas wax type finishes are relatively easy to repair and reapply, and act as a protective barrier over the coating sealer.

When do you use a penetrating versus a coating type sealer? A good rule of thumb is that the denser the tile, the more important it is to use a penetrating versus a coating type sealer. Although penetrating type sealers can be used virtually on any type of porous stone or tile, coating type sealers should be used primarily on only the more porous tile and only unpolished, textured stones. Current sealer technology suggests that polished stone such as marble or granite should be sealed only with penetrating (impregnator) type sealers.

Sealers are not permanent, and all varieties will eventually require reapplication. It is encouraging to note that sealer technology has improved greatly in recent years and today, there are water-based, penetrating sealers that can provide an expected life of up to 15 years before needing re-application. A premium penetrating-type sealer not only penetrates the tile or stone and is therefore not subject to surface wear, but also should possess excellent chemical resistance to both acidic and strong base cleaners as well as UV stability.

Other important features to be considered when selecting a sealer are:

• 1. Coefficient of Friction (slip-resistance); the sealer should not render the tile or stone slippery and create a slip-fall hazzard.
• 2. Breathability (moisture-vapor transmission); this refers to the sealer allowing any moisture from the tile or subsurface to pass through the sealer as a vapor. This is especially important in exterior installations.

The selected sealer should provide the stain resistance required given the area and contaminants present. Other key considerations include the hazardous ingredients that may be in the sealer. This is most often a consideration when using solvent based sealers, with necessary precautions taken during the actual sealer application through the initial curing stage.

Sealers should always be selected with a priority given to "lowering ongoing maintenance." Don't select a sealer where the end result may be a minimal improvement in stain resistance and a large increase in maintenance requirements.

When selecting a sealer, don't hesitate to contact the sealer manufacturer with any questions you may have. Making the proper choice the first time can eliminate the hardship of re-addressing a tile or stone installation where the wrong sealer was selected..

Bill Tran
Vice President, Sales
Aqua Mix Inc.