All Porcelains Are Not Created Equal By Estelle Davis

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.