Tiling business. Organization of production. Overview of machines for the production of polymer sand tiles

I stage. Clay selection

The quality of the clay directly affects how durable and aesthetic ceramic tiles will be. It is best to take the clay that is usually used to make pots: not greasy, but not too sandy. Because natural tiles made of too oily clay will warp and crack when dried, and those made of skinny clay will intensively absorb moisture and do not tolerate frost well.

Clay should be viscous, soft and clean. Here's how you can determine its quality:

1. Method 1. Crush the lump of clay and throw it with force on the floor. It should flatten out like dough, into a cake - without cracks and without crumbling pieces.

2. Method 2. Rub the clay between your fingers - sand should not be felt.

3. Method 3. Knead the clay and try to mold it into shapes. It must be plastic.

And for even greater reliability, one ceramic tile is made from the selected clay - for testing. If the clay was suitable, then:

the color will be even, red;

The surface will have an even vitreous coating, without any distortions or cracks;

· high-quality ceramic tiles lowered into the water should not increase much in weight;

· at impact on a tile the clear metal ringing will be heard;

· the ready ceramic tile put on two bars should easily sustain the adult person standing on it;

· the total volume of one tile during firing did not decrease by more than 5%;

· at a break, a good ceramic tile will be of the same color without bubbles.

II stage. Clay preparation

Once a good clay is selected, it can begin to be prepared for processing. Usually clay is harvested for tiles at any time of the year, but it still has to overwinter. The production of ceramic tiles at home begins with the selection of quality clay. The strength of the future coating depends on the raw material. Clay should be non-greasy, not overly sandy, soft, viscous and clean.

Important: if greasy clay is used, then after drying the coating will immediately crack and lose its shape!

After choosing the clay, it is time to prepare it for production. In whatever period the clay is mined, it must definitely overwinter. Clay ridges are piled on the surface of the earth: in autumn water accumulates in them, in winter it freezes, and in spring it thaws. So clay will acquire the qualities of strength necessary for the production of tiles.

Important: you can freeze for several winters.

Qualitatively frozen clay is soaked, and after a few days they begin to knead. At this stage, you can use a special pug mill, but you can knead with your feet. Forms are filled with prepared raw materials. After the tile has acquired the desired shape, the frame is removed and the tile is dried. Making tiles with your own hands is a complex process that requires experience and knowledge.

So, the clay taken out of the ground must be folded on the surface of the soil in the form of ridges 2 m wide and 70 cm high. Such ridges are usually called stacks. This is how the clay will have to lie until warm - in the fall it will get wet from the rains, freeze in the winter, and thaw in the spring. After all this, it will be much easier to process it. And in order for the clay to freeze better, it is advisable to periodically mix the stacks and even fill them with water. After all, the longer it freezes, the better. Even if the clay lies like this for several years, it will only benefit it.

III stage. Clay preparation for processing

Before processing, the frozen clay must be soaked, and after two or three days it will be possible to start kneading. To do this, there is a pug grinder, which you can make yourself from a wooden barrel or thick boards in the form of a box. It is necessary to insert a wooden or iron axle inside the pug mill, and iron knives are screwed onto it in a helical way. The mechanism is similar to twisting meat in a meat grinder. And for better mixing, you can put additional knives on the sides of the pug mill. It is better to mix the clay itself at least twice.

IV stage. Shaping the shingles

The easiest way to make a flat ceramic tile for roofing. To do this, you need a wooden or iron molding frame with a handle with dimensions of 33x21 cm, and a little more than 2.5 cm thick. and also at the top to have a cutout for the spike.

So, a frame is placed on the desktop, and a plate with a cutout is placed in it. All this is sprinkled with ash or dry sand. A large lump of already crumpled clay is placed on the table nearby and it is shaped into a cube. Next, several layers with a thickness of 2 cm are cut with a stretched thin steel wire.

Now one layer of clay is taken, placed in a frame and strongly compressed where the tile should have a spike. Then a lump of clay is added and a rolling pin soaked in water (so that it does not stick) is cleaned off the excess clay from the frame itself. After all this, the frame must be carefully removed, and the ceramic tile itself is covered with a drying board. Next, you need to turn it over and remove the board. And that's all - the tiles can be taken to the drying shelves. The main thing is that when forming the tile, the layer should be cut so that the frame is completely filled, because after firing the added clay will lag behind.

Forming Roman or Dutch tiles is a little more difficult, but this technology can be mastered without any experience. There is even a statistic that only one worker is able to make such 500 blanks per day.

But the installation of natural tiles has its own characteristics. So, for the ridges of the roof, a special ceramic tile, called ridge, is being prepared.

V stage. Drying clay tiles

The formed ceramic tiles should dry well - slowly and evenly over the entire surface, otherwise cracks cannot be avoided. And the drying time depends on how cool the clay was mixed - the damper it was, the faster the water will come out.

Drying tiles can only be indoors, or at least under a canopy. To do this, you need to make temporary shelves or bricks as coasters in advance. And it will take 10 days to dry.

VI stage. Treatment

Burnt natural tiles do not always turn out to be perfectly even in color, and therefore they are often pre-treated with additional processing. Basically it is glazing. The tile is covered with a special vitreous layer, which makes it more beautiful. But this is quite an expensive pleasure, and therefore more often irrigation is applied to the tiles, which is made from pure red oily clay. It is first dried and ground, and then diluted with water like thick milk. Before the firing itself, the clay is dipped into such a solution and again placed on the drying rack. After firing, the tile turns out to be even red in color, with improved qualities and an extended service life.

VII stage. Burning

Firing is the most crucial moment in the production of tiles. Tiles need to be fired in special ovens, which are called batch ovens. These can be seen in old Dutch villages, and it is quite possible to design something similar according to a similar scheme on your site, however, of a smaller size.

So, a tile kiln consists of four sections - a furnace, an ash pan, a firing chamber and a pipe. A wall with holes is installed behind the firebox, which separates it from the firing chamber. Once the chamber is fully loaded with shingles, a temporary perforated wall will be laid out at the back of the chamber. Also, in such a furnace, a special valve is installed to reduce or increase traction, and the furnace itself is covered with a vault.

By the way, behind such a furnace there is always a larger opening for unloading and loading tiles. And at the time of firing, it is laid with bricks or covered with sand - to reduce heat loss. But they always leave a small door - to monitor the firing process and take samples.

The tile itself can be laid for firing in different ways: vertically if it is a Dutch or Tatar tile, and sideways on an edge if it is flat. But any tile should stand upright, at a small distance from each other and without any slope. So that it does not bend over, you can jam it with pieces of broken and already burned.

It is necessary to fire the tile to such an extent until it becomes slightly vitrified on its surface. In general, vitrification is a sign of burnt tiles, but it is better to overexpose it in the fire than underbake it. Usually, the longer the tile lasts in the stove, the stronger it is. And the installation of ceramic tiles with burnout is a guarantee of special strength and durability of the roof. But without fanaticism - it is quite possible to completely burn the clay.

VIII stage. Sorting

After the tile has cooled, it is unloaded from the oven and sorted. So, for the roof, all of it should be straight, sonorous, without cracks and evenly colored. And the rest of the tiles can be safely used to cover the canopies. Shingles should be stored under a canopy, with good protection from snow and rain. And the bottom rows should not lie on the ground, but on the boards.

All tiled roofs are durable, easy to maintain and very beautiful. And the installation of ceramic tiles will not be difficult even for a novice builder - everything is extremely simple. The steeper the slope, the better for the tile itself - the snow will linger on it less. But in hot areas, tiles can also be used to cover sloping roofs.

It's amazing how life changes. Much of what we now habitually buy in stores ready-made, 100 years ago people did it with their own hands: they ground flour, baked bread, spun, wove, etc. They also built houses on their own, harvesting, including building materials: sawing wood, making boards and bricks, burning lime.
But even in periods closer to our time, people were forced to return to economic "self-service", recalling old-fashioned methods and technologies. They were forced to do this either by the post-war devastation and the accompanying commodity hunger, or by being abandoned to the mercy of fate by the authorities. From those times, not only objects made by the hands of our grandfathers or houses built by them remained, but also a mass of literature devoted to the handicraft production of a wide variety of goods.

It is very interesting to hold such books and pamphlets, usually published in the 1920s or 1940s, in your hands. And this interest is not only historical. The fact is that the traditional technologies to which these manuals are devoted are of interest today due to the fact that they were based on the use of predominantly local natural materials - environmentally friendly and cost-effective. And this is a reason to become interested in them for people who are tired of the dirt of modern production and constantly rising prices in the construction markets.
The booklet of the engineer A. Skachkov "Fireproof Roof of Clay Tiles", published in 1925 in the series "Insurance Library of a Peasant", also belongs to books of this kind. It tells in detail how to make clay tiles with your own hands. We provide an abbreviated description of this technology.

Clay selection and preparation

The quality of clay for tiles has always been of great importance. The best clay is the one from which the pots are made, not greasy or sandy, but medium. It should be clean, soft and viscous. A tile made of very oily clay warps and cracks when dried, while lean clay turns out to be very weak, strongly absorbing water and frost-resistant.
But even very oily or very lean clay can be adapted for tiles. To reduce the fat content, fine clean sand or finely crushed bricks, pots, and tiles should be added to the clay. If the clay is too thin, then sand can be washed out of it.

There are many easy ways to find out the suitability of clay for tiles, here are some of them:

· A crumpled lump of clay, thrown with force on the floor, should flatten like dough, without cracks, into a cake, and not crumble into separate pieces.

When rubbing the clay between the fingers, no sand should be felt.

· Well kneaded clay should be easy to take and keep all the forms that it is given (should be plastic).

But the most reliable way to find out the suitability of clay is to make several trial tiles from it. With good clay, the finished tile has an even red color, there are no cracks or distortions on it, when it is struck, it emits a clear metallic ring, and when lowered into water, it does not greatly increase its weight. In addition, being placed on two bars, it should freely withstand a person standing on it, have a light vitreous coating on the surface, and be of the same color and without bubbles at the break. It would be good if, during drying and firing, the size of the tiles would decrease by no more than 5%.
After selecting and harvesting clay, it must be prepared for further processing. For tiles, clay is harvested at any time of the year, but it must definitely overwinter. Clay taken out of the soil is piled on the surface of the earth in the form of long ridges 1.5-2 m wide and 0.7 m high, at any length. These ridges are called stacks. In them, from the autumn rains, the clay thoroughly gets wet, during severe frosts it freezes, and in the spring it thaws again. As a result of these processes, clay acquires qualities that facilitate its processing.
To make the clay freeze better, the stacks are mixed from time to time and filled with water. The longer the clay is refrozen, the better it becomes. You can freeze it for several winters. Frozen clay is soaked before processing and after 2-3 days they begin to knead. It is best to do this in a pug mill, although you can knead the clay with your feet.
A pug grinder can be made from a large wooden barrel or from thick boards in the form of a box. Inside this box, an iron or wooden (oak) axle is inserted, on which iron knives are screwed. When the axis rotates, the clay thrown from above is cut by knives and directed downwards, towards the hole, just as it happens with meat in a meat grinder.

In order for the clay to mix better, sometimes additional fixed knives are placed on the sides of the pug mill itself. A carrier is attached to the top of the axle, into which oxen or horses are harnessed and driven in a circle. It is better to mix the clay twice. The wooden pug mill is about 1.5 m high, 1.06 m wide at the top, and 0.89 m at the bottom. The iron axle is 2.8 m high, and the length of the knives is 0.35-0.45 m with a blade width of 10 cm and a thickness of 3 cm. The carrier is made 8.5 m long. With one horse, two or three workers can knead about 15 m3 of clay in 8 hours.

Clay or ceramic tiles are one of the best roofing materials that have been used in construction for a very, very long time.

Its advantageous advantage is a special installation system that avoids visible joints, as well as groove fasteners, which create a very good waterproofing of the roof.

In addition, clay tile roofing has the ability to resist wind due to its weight.

Snow is evenly distributed over the roof of this material, which minimizes the possibility of large snow masses coming off. It also has good sound insulation and is an environmentally friendly material.

Along with all the advantages, the clay version has one drawback - its high cost. However, it is quite possible to make tiles with your own hands. Below are tips for making. It's also easy, it's like making a bench with a backrest with your own hands.

How to choose the right clay

It should not be greasy (otherwise it will crack during drying) or contain a lot of sand (does not tolerate severe frosts and absorbs water well). The breed that uses pots for making is ideal for this.

There are several ways to determine the suitability of the source material:

Take a lump and throw it on the floor using force. Good clay will flatten into a cake. If the lump crumbled into pieces, such source material will not work.
Rub a piece of soil in your hands. There should not be a feeling of sand on the fingers.
It should resemble plasticine to the touch and retain the shape attached to it.

You can make a number of test copies. If the clay is good, the resulting products will have the same red color. It will also turn out without cracks and curvature. Also, if you put it on two supports, it will support the weight of an adult.
How to process clay

It can be cooked at any time of the year, however, it must be left for at least one winter.

Take it out of the ground and fold it in rows. The width of the rows should be 1.5-2 meters, the height - 0.7 meters. The length can be any. Thus, in autumn the clay gets wet, in winter it freezes, and in spring it thaws. It is best to freeze the clay as long as possible. Therefore, periodically the rows are mixed and filled with water.

Before you start processing clay, it must be soaked. You need to crush it in a pug mill, a few days after soaking. Such a device is made from a wooden barrel or built in the form of a box of thick boards. An axis is inserted into the box, on which helical-shaped metal knives are mounted. A carrier is constructed from above for a horse or a person.

How to shape tiles

It is easy to make flat tiles yourself. For this, a so-called molding frame with a movable bottom is used. The frame can be wood or iron. The approximate dimensions of the frame, excluding walls, are 33x21 cm.

Making a simple tile is very easy.

The frame must be placed on a flat surface, which should be even, we insert a plate with a cutout into it. Pour sand or ash on top (must be dry). We take a piece of clay, give it a cubic shape. Then the layers must be cut, while their thickness should not be more than 2 cm. Then we remove the upper bars and cut off the layer, leading the wire along the bars. And so with each subsequent row.

Next, we put the cut clay in a frame, press hard where the spike will be. Excess material is removed with a rolling pin. It must first be wetted so that it does not stick to your hands. Next, carefully remove the frame and take the resulting blanks to special shelves for drying.

Features of drying tiles

If you dry it incorrectly, it will crack. Therefore, this process should be slow.

Drying of blanks is negatively affected by such natural phenomena as wind and sun. It is best to dry the blanks indoors. If it rains, the tiles should be covered. In summer, drying lasts about 10 days.
Firing products

There are many factors that affect firing, including the fuel used for the kiln, the type of kiln, and the experience and skill of the person doing it.

To burn tiles, a special oven is used. It consists of:

Fireboxes. Its length is 1 meter. A special wall with holes separates the furnace from the chamber.
ash pan
firing chamber
Pipes.

Its height is approximately 4.5 meters. At the base, the pipe is 70-80 centimeters, at the top it narrows to 40-50 centimeters. The pipe has a valve to adjust the draft.

There is a hole in the rear wall of the oven where products are loaded and unloaded. During firing, it can be laid with something. This is necessary to keep more heat inside the furnace.

In the chamber, the tiles are laid either vertically or sideways on a long edge. Be sure to put it at some distance from each other.

The blanks are fired until its surface becomes as if slightly glassy. This effect appears if you burn the products.

How to properly trim workpieces

Tiles do not always get the desired even color. One way to fix this is glazing. Products are covered with a special glaze, which not only gives it the desired color, but also makes it more durable. But then the price also increases significantly.

Also for finishing use special watering.

It is usually made from greasy red clay. Before living, dry clay is dipped into this solution and left on the drying shelves. Watering not only makes the tiles stronger, but prolongs their service life.

After firing, the product is removed from the furnace and sorted. Even color, without cracks and chips are used for the roof. Finished products are stored under a canopy. At the same time, the bottom row should not be placed on the ground, it is better to lay boards.

So, following these instructions, you can make your own roof tiles.

Tile molding

The easiest way to mold a flat tile. For its manufacture, it is necessary to have a wooden or iron molding frame with a handle. The internal dimensions of the frame are 33x21 cm with a thickness slightly larger than 2.5 cm.

A plank (movable bottom) is attached to the frame, which must exactly pass through the frame and be 1.25 cm thick, and have a cutout for the spike at the top.
Making a flat tile is simple. A frame is placed on the desktop, and a plate with a cutout is placed in it, and all this is lightly sprinkled with dry sand or ash. Nearby on the table it is necessary to put a large lump of crumpled clay and give it the shape of a cube. Then, several layers 2 cm thick are cut with a bow with a string of thin steel wire. This is easy to do in a "formwork" of wooden bars 2 cm thick. After forming the cube, the upper bars on each side must be removed and cut the layer, leading the bow along the bars. After that, you need to remove the next row of bars and repeat everything.

After that, they take one layer of clay and put it in a frame, press hard in the place where the spike should be, and then add a lump of clay here. After that, they take a rolling pin, wash it in a tub of water so that clay does not stick to it, and clean off the excess clay from the frame, after which the frame is carefully removed. A drying frame is placed on top of the tiles, they are turned over and, having removed the plank, the tiles are taken to the drying shelves.
When molding tiles, it is necessary to cut layers of such a size that they fill the entire frame, since the addition of clay is harmful and, after firing, lags behind the tiles. The molding of Tatar (Roman) or Dutch (grooved) tiles is also described in the book by A. Skachkov. This process is somewhat more complicated, but, as experience shows, any person masters this technology in a day or two. In a day, one worker can mold from 500 blanks.
For roof ridges, a special tile is prepared, which is called ridge.

Drying tiles

Proper drying of shingles is of great importance. Rapid and uneven drying can warp and crack tiles, so drying should be slow and even across the entire surface of the tiles.

The damper the clay was during molding, the easier water comes out of it during drying, and vice versa - the steeper the clay was mixed, the slower the tile dries. This may cause more cracks.
Drying tiles is very harmful effect of the sun and wind. Therefore, it is better to dry the tiles indoors or under a canopy. In a small production, tiles are placed on temporary shelves made of boards and bricks instead of stands. Such shelves are easy to disassemble and fold, and they do not require any racks or nails in the construction. In case of rain or strong sun, the tiles are covered with matting or straw mats. Drying time in summer averages 10 days,

Roof tiles firing

Firing is the most crucial moment in the production of tiles. Proper firing depends on fuel, kiln design, skill of the worker (kilner) and many other factors.
Tiles are fired in special kilns, the simplest of which are batch kilns.

The furnace is divided into four main compartments: the firebox, the ash pan, the firing chamber and the chimney. The internal dimensions of such a furnace are impressive: 2 m wide and 4 m long. The firebox is 1 m long. A wall with holes is installed behind it, separating the firebox from the firing chamber. After the firing chamber is loaded with tiles, a temporary wall with holes is laid out in the back of the chamber. In some furnaces, they do not do it. The height of the pipe for such a furnace is not very large - about 4.5 m. The dimensions of the pipe at the bottom are 70x80 cm, and at the very top - 40x53 cm. A valve is installed in the pipe to increase or decrease thrust. Cover the oven with a vault.

At the back of the oven there is a large opening for loading and unloading tiles. During firing, this hole is laid with bricks on clay mortar and covered with sand to reduce heat loss. Sometimes a small door is left here to monitor the progress of firing and take samples.

Different tiles are laid in the oven in different ways: Dutch and Tatar tiles are placed vertically, and flat tiles are placed sideways on a long edge. Tiles should stand vertically, without tilt, at a small distance from each other. So that it does not bend during firing in one direction or another, it is slightly wedged with broken fired tiles.
It is best to lay the tiles in the furnace in separate tiers, starting from the wall closest to the furnace and bringing them across the entire width of the furnace to the very top. At the end of the loading of one tier, another is placed, and so on, until the entire furnace is loaded.

After that, the firing starts. It should be carried out to such an extent that the tiles come out slightly vitrified over the entire surface. Vitrification begins to appear when the tiles are slightly burned and the clay on the surface is sintered. In any case, it is better to burn the tiles a little than not to burn them. Tiling finish. Not always the tile turns out an even color. To remove the variegation, give the tile a more attractive appearance and improve its quality, the tile is subjected to various treatments. One of them is glazing. Glaze is a special glassy layer that covers the surface of the tile during firing. The icing comes in a variety of colors, but the cheapest and most common colors are brown and tan. Glaze gives the tile a beautiful look and makes it stronger than unglazed tiles. However, glazing doubles the cost of shingles, which limits the use of this finish.
A more acceptable finish is engobing, that is, applying glaze to the tiles. Watering is made from a special red, completely pure fatty clay, which is first dried and ground, then diluted with water like thick milk and filtered through a fine sieve. Before firing, the dried tiles are dipped into this clay solution and re-placed on the drying shelves. When the tile dries again, it is loaded into the kiln and fired. After firing, the surface of the tile comes out all of an even red color. Watering improves the quality of tiles and increases their service life.

When the tiles are fired and cooled down, they begin to unload them from the kiln and sort them. Tiles for the roof of houses should be straight, evenly colored, sonorous, without cracks and broken corners. The rest of the shingles can be used to cover sheds and temporary roofs. Finished tiles are best stored under a canopy, protected from rain and snow. The bottom rows must be placed not on the ground, but on the boards. Covering the roof with tiles. Tiled roofs are fire resistant, durable, do not require painting or repair, and are very beautiful.
The steeper the slope of the roof, the better it is, since the snow will not linger on it, and the rain will quickly drain. But this rule is true only for certain climatic conditions (sloping low roofs, for example, are acceptable in southern hot areas) and the tiles used.

With flat tiles, the roof must have a rise of at least half the width of the building. The purlins under it are nailed according to the size of the tile, so that it is hooked with a spike at the top, lies on the lower bar and descends no more than 6 cm below it. Flat tiles are covered either in one layer or in two.

The first method is simple, but the roof turns out to be loose and, so that rain does not fall into the gaps between the tiles, strips of tin are placed under these gaps. The width of the strips should be from 9 to 11 cm, and the length should be 4 cm shorter than the tiles. Skates are covered with ridge tiles on moss mixed with clay or lime mortar.
A more durable and dense roof is obtained in two layers. But such a roof is heavier - about 200 tiles go per 1 m2, which weigh about 100 kg (with a single-layer laying - half as much).

We propose to consider the issue of production of clay tiles. So, at the initial stage, the extraction of the clay itself is carried out, which should be of high quality, which will be reflected in the future on the quality of the ceramic tiles themselves at the end of the full production cycle.

Large manufacturers extract raw materials from their own mines located in environmentally friendly quarries. That is why ceramic tiles have such a wealth of natural colors.

At the second stage, the extracted raw material goes through a cycle of technological processing by sieving, grinding, grinding, as a result of which foreign particles are removed from the raw material and the clay acquires a homogeneous mass with the desired consistency.

The third stage consists in shaping the future roof tiles or stamping them by running them through special molds.

Shingles molds

The fourth stage includes the drying process using modern methods, which, unlike the old methods, takes much less time. At the end of the drying process, the tile proceeds to the firing stage, before which some of its varieties can be coated with special compounds. So, for example, a layer of glaze will provide a high level of moisture resistance.

Making clay tiles with your own hands

The tiles are burned at temperatures up to 1200 degrees in a special tunnel kiln for a certain time. Everything - ceramic tiles are ready for use, having received high strength and fire resistance.

Elite class roofing materials

Ceramic tiles can be safely attributed to the roofing materials of the elite class and deservedly so, since this material can last more than 100 years without the need for repairs. If you want a roof that is durable, strong, beautiful and would provide warmth to your home, ceramic tiles will be the right choice.

Despite the fact that the cost of ceramic tiles is an order of magnitude higher than other alternative roofing materials, it will justify its quality. The roof of a house made of this material will delight you, your children and grandchildren with its beauty.

Considering Germany, the leader in the production of this roofing material, we can say that German tiles are indeed a high-quality building material.

Having bought a ceramic tile, it is worth considering the issue of its installation, since this process requires high professionalism, on which its further operation depends. In this regard, we recommend that you contact the specialists of companies that offer customers not only the sale of tiles, but also its installation and further maintenance.

Ceramic tiles

It's no secret that the roof of the house is an element of beauty and reliability, protecting the house from atmospheric precipitation. Due to the fact that there is a wide choice of roofing materials on the modern market, it is not so easy to make an unambiguous choice.

For those people who prefer the classic version of the roof, ceramic tiles will be an exceptional option, especially if you take into account its uniqueness. By purchasing ceramic tiles, you are guaranteed to make the roof of your home reliable for many years. Along with the high physical properties of this coating, clay tiles are beautiful and quite aesthetic. One has only to pay attention to how many houses in Europe have such roofing.

Installation of ceramic tiles

Despite the high cost of ceramic tiles, unlike other roofing materials, it makes sense to buy it, for which there are weighty arguments. Clay tiles can be used for roofing both antique and high-tech buildings, depending on the profile and color of the material you choose.

New product range of the company

If you ask in the search line of the browser a request to purchase ceramic tiles, at the output you will receive many offers from companies offering the widest selection of this roofing material. Since the sale of ceramic tiles is very popular today, it is accompanied by the necessary service for this, including the provision of advice on the method of its installation.

As a rule, the most popular manufacturers of this roofing are from Germany, Austria, Estonia, Slovakia and others. Customers will be surprised by the variety of tile coverings, in particular glazed, agglomerated, agnob or noble agnob. Each of these coatings is distinguished by its aesthetic appearance and physical properties.

Video: Production and installation of ceramic tiles

Ceramic tiles are the oldest type of roofing with a long history. Despite the huge variety of modern finishing materials, it is a confident leader in its segment. The production technology for this period has not changed, only the equipment for the production of ceramic tiles has been improved. Consider this popular type of roof, how it is made and the benefits.

Production technology

The complexity of the technological process implies that industrial equipment is used for the production of ceramic tiles, which excludes the possibility of handicraft production.

The prepared clay is mixed with water until a plastic homogeneous mass is obtained, compacted and squeezed out in the form of a flat ribbon, which dissolves into fragments of a certain size. During the drying process, it is mandatory to control the temperature and humidity of the air in order to avoid uneven shrinkage, cracking and curvature of the finished product. Firing completes the manufacturing process, giving the tiles strength and water resistance.

Heat treatment is an energy-intensive cycle, which is the reason for the high price of clay products. The ceramic tile production line is mostly an automated process that increases productivity and improves product quality.

The natural color of the tile is terracotta, therefore, in order to change it, the tile-shaped surface is coated with special compositions during firing:

• engobe - white-burning or colored clay, providing a stable color;
• glaze - a vitreous coating applied to the product and fixed by firing.

Using the latest equipment for the production of ceramic tiles, failures due to the "human factor" are completely excluded. Control at all stages of the processing lies with automation, largely due to this, a very high quality of the product is achieved.

Protective cover fastening

The installation work includes laying insulation on the rafters, waterproofing and vapor barrier layers, counter-lattices, and on top - lathing beams. The step of wooden flooring is affected by the heavy weight and size of ceramic tiles. It is calculated individually and depends on the model. The marking of the rows is made with a cord.

The roofing is laid from right to left, then from bottom to top. The large weight of ceramic tiles determines their placement on the roof prior to installation - in stacks of 5 pieces to evenly distribute the load on the crate and rafters.

Fasteners are made with galvanized screws. With a slope of more than fifty degrees, the roofing material is additionally fixed with clamps. Grooved tiles should be laid with a single overlap, and flat tiles, respectively, with a double overlap. The tile located in the top row should overlap the joints of the two bottom ones.

Installation of ceramic tiles is a job that requires high qualifications, so it should only be trusted by professional roofers.

Advantages of ceramic tiles

Only by strictly observing the technology and using specialized equipment for the production of ceramic tiles, you can be sure that the durability of this roofing material will be about a hundred years. The advantages of a unique coating include:

• environmentally friendly raw materials;
• reliable sound and heat insulation;
• ease of repair;
• low water absorption;
• resistance to weathering, temperature extremes;
• minimum waste during installation.

Cons of clay roofing

The disadvantages of natural tiles are a small number:

• high cost, which is covered only by an increased service life;
• the impossibility of mechanizing installation work, an increase in the cost of arranging the truss system by 20%, while the reliability of the coating is highly appreciated;
• the choice of colors is limited to natural shades only.

The appearance of a house covered with ceramic tiles becomes aesthetically attractive, exuding coziness and comfort. This roofing gracefully repeats all the curves of the roof, looks spectacular, standing out with the restrained nobility of natural materials. This quality is truly time-tested.

Minimum output for tiles 3000 pcs/day

This information is presented for the purpose of a more detailed study of the basic features of the technology for manufacturing various building materials from clay, followed by firing.

I. The general composition of the line and the main nodal elements
1. Preparatory unit. Knot - 1 (1 set)

(1) Air drying of raw materials until moisture reaches 13% (for loader) →
(2) Belt feeder with hoppers, model TL-WLJ-PD6 (for transportation) →
(3) Conveyor type TL-SSJ-PD11 (for transporting raw materials) + 2 magnetic traps, type TL-RCBD-6.5 (to protect equipment from metal objects) →
(4) High-speed mixer crusher, type TL-XSJ-DG800 (for preliminary crushing and mixing of raw materials, obtaining a fraction of not more than 5 mm) →
(5) Conveyor, type TL-SSJ-PDPD12 (for transporting processed raw materials) →
water supply system (for mixing raw materials and achieving a moisture content of 18%-22%) →
(7) Conveyor type TL-SSJ-PD13 (for transporting recycled wet material) →
(8) High-speed mixer-crusher, type TL-XSJ-DG800 (for preliminary crushing and mixing of raw materials, obtaining a fraction of not more than 1.5-2 mm) →
(9) Conveyor, type TL-SSJ-PD14 (for transporting prepared material) →
(10) Mixer-granulator, type TL-ZLJ-YPA (for the subsequent processing of raw materials by granulating them, which significantly improves the quality of the final product before the subsequent aging of clay for 3-6 days. This is especially true for raw materials containing an increased amount of sand .) →
(11) Conveyor, type TL-SSJ-PD15 (for transporting semi-finished products) →
(12) Warehouse for storage (aging) of clay (laying out of clay for 3-6 days after its granulation, to ensure higher quality end products) → Node-2
(13) Automatic control system (for preparation before further use of the material)

2. Automatic extrusion & semi-dry molding. Knot - 2 (1 set)


Description of the basic principles of the technological process:
(all subsequent processes up to item 20 are carried out automatically)
14) Conveyor, type TL-SSJ-PD21 (for transporting the prepared semi-finished product to ...) →
15) Belt feeder with hoppers, model TL-WLJ-LB6 (for feeding and dosing material) →
16) Conveyor, type TL-SSJ-PD22 (for transporting prepared quality material to the extruder) →
17) Vacuum extruder, type TL-CXJ-B40-30 + tile forming nozzle, type TL-JCM-RT-ST, or other nozzle (for primary tile forming) →
18) Automatic tile molding machine, type TL-AUTOYWJ-1W + tile mold, type TL-SYM-RT-ST or other mold (to form a clear shape and correct geometric dimensions of the tile) →
19) Conveyor-type manipulator for capturing and transferring products, type TL-JXSSSJ-JZ (for moving freshly molded products from the molding zone to the post-processing site) →
20) Loading transport pallets into drying plants (carried out by workers) *** 0 → Node-3
21) Automatic control system (for preparation before further use of products)

Description of the basic principles of the technological process:
(not for tiles)
20) Transport pallets (for loading by workers or automatic system***2 to) →
22) Multi-Tracks Dryer (for drying products & after hot air treatment from ovens, the presence of humidity should be less than 3-5%. After drying, the products are transported to the unloading area and unloaded by workers or automatically ***3) →
23) Transport system (for transporting products in the oven) →
24) Tunnel kilns (for firing products at a temperature of about 1150℃ until the final product is ready) → Sorting and packaging of the finished product (performed by auxiliary workers or automatically***4) +
25) Automatic control system (for drying and firing)

***0, 1, 2, 3, 4---We need to know what type of fuel you prefer to use, its calorific value and characteristics in order to make the best stove offer for you. This is very important to maintain the correct temperature during firing. And also we need to know your investment budget in order to give you the best offer, and in particular, in order to know for which mode to prepare an offer for "Node - 3" - automatic control or not.

II. Description of the main equipment in the line.

1. Twin shaft mixer, type TL -JBJ -300 II

Main Technical Parameters of High Speed ​​Double Mill Type TL -XSJ -DG 800
Dimensions LxWxH(mm)	Productivity (tons / hr)	Particle size inlet / outlet (mm)	Motor power (kw)	Weight (kg)
3.150 x 1.580 x 1.550	15~25	≤100 / ≤2 ~ 5	67	≈ 6000
Features of this type
1.Special design for fine grinding and screening process. 2.Some modifications may have their own characteristics; type CG double reduction rollers, type DG double hammers, type CX - impact screen grinding method, and type GS4 - rotary screen, to perform all possible grinding options.

4. Belt feeder with hoppers, type TL -WLJ -PD 6

5. Vacuum extruder, type TL -CXJ -B 40-30

Main Technical Parameters of Vacuum Extruder Type TL -CXJ -B 40-30
Dimensions LxWxH (mm)	Capacity (VFD adjustable) (tons/hr)	Max shaft diameter (mm)	Nominal screw diameter (mm)
4.600 x 1.800 x 1.300	5 ~ 8	￠162	￠400 / ￠300
Vacuum pressure (mpa)	Mixing / Motor power (kw)	Extruding pressure (mpa)	Weight (kg)
≤ - 0.095	45	3.0	≈ 6000
Designed specifically for the production of ceramic tiles, bricks, and other high quality cubic elements. The all-metal body, special hard-alloy screws and a reliable gearbox ensure the stability of the equipment and the quality of the products.

6. Modular tunnel ovens.

1. One set consists of 148 meters of tunnel ovens
The proposed tunnel ovens are a prefabricated structure of individual modules that can be assembled in a short time at almost any job site. The preliminary proposal contains recommendations for the use of natural gas as a fuel. Each set of tunnel ovens consists of 41 modules (each 3600 mm long).
All modules are made of special steel reinforced with hot-rolled steel profiles and coated with fire-resistant paint. The joints between the modules have special lock slopes that provide a smooth transition between them with a reliable hermetic connection.
Tunnel kiln length: 1,480,000mm, Inner/outer tunnel width: 2650mm / 3600mm
Size of mobile racks: 3600 x 2600 mm, Height of transport pallets: 620 mm

2. One set of double hot air ducts - 73 meters
The hot air ducts are equipped with exhaust fans and temperature detectors that regulate the humidity and temperature inside.
Each channel can accommodate up to 19 mobile pallets, for a total of 38. The ceiling of the dryer is made of reinforced concrete slab. The dryer itself is equipped with an easy-to-mount sliding gate. The dryer and air preparation system are designed, among other things, to accommodate standard bricks in it.
Dryer length: 73,000mm, Dryer inner/outer width: 5250mm / 5750 mm Mobile rack dimensions: 3600 x 2600 x 620 mm

7. Brief final conditions.

1 Appropriate arrangements for sending company specialists abroad (to Russia, Kazakhstan, Georgia ...): if necessary, the equipment supplier can send technical specialists to the buyer to carry out equipment installation, configuration and commissioning. In this case, the buyer pays the costs associated with travel, accommodation and meals for specialists, as well as pays for their work at the rate of USD 30 for each working day per person.

2 Power consumption system: three-phase, voltage 380V／50Hz (or other system according to customer requirement).

3 Terms of delivery and installation of equipment:
Manufacturing and delivery of equipment are carried out within 90 days after the signing of the contract and receipt of prepayment; installation of equipment is carried out within 60 days.

4 Ensuring the quality of equipment and services provided:
a) The warranty period of the equipment is one year, provided that it is operated in accordance with its functional purpose;
b) Sending qualified personnel to adjust and adjust the supplied equipment; c) During the warranty period, the buyer is fully serviced on all issues related to the management of equipment by telephone (fax), postal and other form of communication;
d) To ensure the normal operation of the equipment, the company ensures the elimination of problems and the necessary repairs, provided that such problems arose during the warranty event;
e) Installation and test run: During the installation and testing of the equipment by the manufacturer's technicians, in compliance with the norms and standards established by the Chinese quality system, it is desirable that during this period, the buyer's technical personnel work together to improve their skills and training. This is the best way to get acquainted with the equipment and its possible malfunctions.

5 Conditions of the offer fulfilled by the customer:
a) The Buyer independently ensures the supply to the location of the equipment: gas, water, electricity;
b) The Buyer independently ensures the organization of production areas and premises necessary for the placement of equipment;
c) The Buyer independently ensures the availability of the necessary tools, fuels and lubricants, special equipment, etc. at the location of the line;
d) The Buyer is solely responsible for other necessary elements not mentioned in this offer.

6 Packing of equipment is carried out on transport pallets, taking into account all the requirements necessary for sea transportation.

7 Payment terms: Payment is made in US dollars on the terms of T/T:
a) Thirty percent (30%) of the basic price, in the form of an advance payment, is paid within 7 days after the signing of the contract;
b) Sixty-five per cent (65%) of the total contract price must be paid upon notification of the buyer that the equipment is ready;
c) Five percent (5%) is paid within 7 days after receiving the equipment and checking its quality and completeness.

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For such an elite and noble roofing material as natural tiles, raw materials are required, which are absolutely not rare. This is what ceramics are made of. Next, we'll show you how.

And we will also tell you about well-known brands of roofing and tell you if there is Russian production.

Raw materials and equipment

Ceramic tiles should have a high fat content and be fusible. As a rule, plants for the production of this roofing material are built near quarries with such raw materials.

Of the equipment for the production of ceramic tiles, a mixing device is used (where the clay is turned into a homogeneous mixture), as well as a special press, with which the tiles are given a certain shape. You also need a drying chamber and a special oven capable of reaching an internal temperature of up to a thousand degrees.

Depending on the brands and complexity, the equipment as a whole can cost from three hundred and fifty thousand to one and a half million rubles.

The following video will tell you how ceramic tiles are made:

Manufacturing technologies

Factory

The clay extracted from the quarry is transported by conveyor belt to the warehouse. After some aging, it is processed using a wheel mill, grinding the material (this way it mixes better with water later).

1. Under production conditions, at the first stage, in a special mixer, clay is mixed with water and plasticizers are added. The output is a plastic homogeneous mass.
2. Then this mass is subjected to pressing (either belt or stamping method). At the same time, electronic control is carried out, as a result of which the products are neat, without errors in size.
3. Roofing elements dried in a special chamber are sent to the kiln, where they are fired at a high temperature. The finished tile is left in its natural form or coated (vitreous glaze or clay engobe).

With my own hands

Let's start with the selection of raw materials - the clay used must be sufficiently clean, plastic and soft.

• When rubbing the lump between the fingers, sand should not be felt.
• And when throwing a clay lump on the floor, it should not crack, crumble. It is optimal when it is flattened (like dough).

It’s not bad to make just one product for testing. If it turns out to be uniform, red, without bubbles at the break, does not decrease much during firing, and rings when struck, then everything is fine. The clay is well chosen.

Clay selected for tiles should lie through the winter. To do this, it is stacked on the surface of the earth in piles of two meters wide, the height of which is seventy centimeters.

Well-frozen clay is an excellent raw material. And so that it freezes better, you can periodically water the stacks with water.

In the warm season, clay is soaked for two or three days, after which it is crushed in a pug mill (built from a wooden box or barrel), where metal knives are screwed onto the axis. Then the products are molded using a frame measuring thirty-three by twenty-one centimeters. There is a handle on the side of the frame, and a board is placed below.

• Clay is sprinkled with ash before forming products (it can be replaced).
• Two-centimeter layers are cut with a steel string from a clay lump. They are passed through a frame, covered for a while with drying boards, then carried to the shelves for drying.
• Dry for ten days, in a room or under a canopy.
• Before firing, for decorative purposes, tiles are often dipped in a solution of greasy red clay called glaze. Roasting is carried out in a special furnace. It consists of an ash pan, a furnace and a firing chamber, and a pipe. Behind there is a loading opening through which both lay, and take out a tile. Products are fired vertically or sideways on edge.

This video will tell you how ceramic tiles are produced at the factory:

Notable Manufacturers

BRAAS

More than a hundred factories around the world belong to the company of the same name that produces this tile. For Russia, it is produced by a Russian-German enterprise. The tile of this brand is distinguished by the presence of additional ventilation gaps, high reliability (the tiles are connected by a lock).

The manufacturer gives a guarantee for thirty years, but the roof definitely withstands a hundred years. The price of products for one piece of ceramic tiles Braas (BRAAS) is from 100 to 300 rubles, per square meter - from 1.3 to 3.8 thousand rubles.

Koramic

Tiles made in Germany with a wide variety of sizes, profiles and shades. Suitable for any roofs: both pitched and hip. Doesn't fade over time at all.

In any weather (and at any time of the year). A square meter of Koramic ceramic tiles will cost from 1.1 to 1.8 thousand rubles.

Creaton

Another high-quality European brand of ceramic tiles is Creaton. Differs in reliability and a wide model range.

Twenty profiles are painted in more than a hundred different shades. This is anthracite, and green moss, and the color of a noble red wine. This brand even has blue and graphite gray tiles. One piece will cost about 75 to 150 rubles.

This video will tell you how Creaton makes its ceramic tiles:

Robin

Another German brand of ceramic tiles, Roben, which immediately speaks of her. Modern high-class European equipment makes it possible to obtain the most accurate dimensions and avoid marriage.

For coloring, natural pigments are used, allowing to obtain pure natural colors. Two-color models (“autumn leaf”, for example) are very interesting. The price of one piece of tiles ranges from 84 to 100 rubles. This brand of ceramic tiles competes with the Chekker brand.

Tiles of Russian production

Today in Russia there are no enterprises for the production of ceramic tiles. There are only joint productions. In particular, as already mentioned, the company BRAAS.