by: Ms. Ang Pek Lay FMM Malaysian Ceramic Industry Group (MCIG) 13 October 2016 REHDA Institute

1. by: Ms. Ang Pek Lay FMM Malaysian Ceramic Industry Group (MCIG) 13 October 2016 REHDA Institute Getting it Right 1- Wall & Floor Tiles

2. Presentation Outline • Manufacturing Process Flow • What are Ceramic Tiles • Advantages of Ceramic Tiles • Classification and Types of Tiles • Technical Specification - MS ISO 13006 Standard • Labelling • Choosing the Right Tiles • Installation Guideline • Some common tiling failures • Costing • Care & Maintenance • Warranty • Q&A

3. What Are Ceramic Tiles? • Ceramic tile is defined as product that is manufactured from a mixture of natural inorganic materials, comprising of mainly • Clay (main component) • Feldspar(main component for Porcelain tiles) • Limestone (main component for Wall tiles) • Silica Sand • Colour Pigments • this is processed and pressed into shape and then fired to high temperatures (up to 1220°C) to produce a strong and durable product.

4. Manufacturing Process of Ceramic Tiles

5. Ceramic Tiles can be Glazed and Unglazed Glaze Glazed Tile Unglazed Tile Body • Glaze acts as a impervious coating on the tiles which protect the tiles from getting dirty and stained. • The glaze coating makes the tile easy to clean and maintain.

6. Advantages of Ceramic Tiles AestheticsTiles available in limitless colours, textures and designs DurableCorrectly specified tiles and with proper care, tiles will last a lifetime. Colour-fast Colours on tiles do not fade. Easy to cleanTiles come with an impervious glaze or vitrified surface, make it easy to clean. Fire ProofTiles being fired at a high temperature makes it fire resistant. Chemical ResistantTiles are resistant to most common household chemicals. Low allergy & SafeTiles are inert and unlike many plastic finishes, will not give off any hazardous fumes and are free from V.O.C. (volatile organic compounds)

7. Classification of Ceramic Tiles • All ceramic tiles must conform to the technical requirements specified in • MS ISO 13006. • SIRIM MS logo certifies conformance to ISO standard • Ceramic tiles are classified into different groups according to its WATER ABSORPTION.

8. Types of Ceramic Tiles Common Terminology

9. Types of Ceramic Tiles – ISO/ASTM Terminology (ASTM Classification)

10. Microstructure of Ceramic Tiles GLAZE GLAZE GLAZE ENGOBE ENGOBE ENGOBE BODY BODY BODY BODY Glazed floor tile with 6% water absorption Porcelain tile with 0.1%water absorption Glazed wall tile with 14%water absorption Compact Porous HFW : 1.9mm

11. Ceramic tiles without engobe layer – prone to water mark

12. Porcelain or Homogeneous Tiles?

13. The terminology, HOMOGENEOUS/ FULL BODY TILES is commonly used to describe porcelain tiles. • Homogeneous tile is a product of porcelain tile where the tile have the same colour throughout the whole piece of tile. • To assess whether a tile is homogenous - check for a consistent colour/material throughout the entire tile. • Therefore, HOMOGENEOUS tile is a product type of Porcelain tile since the water absorption is less than 0.5%. HOMOGENEOUS NON-HOMOGENEOUS

14. Glazed Porcelain vs Polished Porcelain

16. Rustic/Structure Matt Lappato

17. Polished Porcelain Tiles

18. Technical Specification- MS ISO 13006

19. Typical Technical Specification for Porcelain Tile

20. Tiles and their packaging shall have the following marking & specification: Labeling & Specification on Carton The Method of Shaping. Water Absorption & Annex Group Nominal Size and Work Size (with thickness) Tile Surface (i.e. glazed-GL or unglazed-UGL) Grade of Tiles (Mark to indicate quality) Country of Origin Descriptive type of tiles Product Code/Shade Code /Size Code Production Date / Production Batch Code Quantity of Tile Per Carton Installation Instructions

21. Choosing the Right Ceramic Tile How to Choose the Suitable Tile for the Right Application? • When choosing ceramic tiles, other than the aesthetic aspects, it is important to consider thetechnical and physical characteristicsof the tile.

22. Wrong Choice of Tiles! Badly worn out glaze after 2 months

23. Installation Guideline- MS 1294: Part 1-4

24. The Tiling System & Its Physical Components concrete or levelling render • All the components are equally important as they areinter-related • Adequate compatibility must exist between them for the system to function collectively • The system can only be as strong as the weakest component (or, in some cases, worse) tile adhesive (bedding material) finishing tile or stone tile grout

25. The Tile Adhesive: Identify the Selection Criteria • Type of tile based on water absorption • Size of tile, ranging from mosaics to large format tiles • Rigidity of support structure eg. slab deflection, vibrations • Slab or wall installation? • Substrate type eg. cementitious or dry wall? • Traffic loads eg high volume, heavy traffic? • Interior or exterior application? • Exposure to water eg periodic wetting / drying? • Installation conditions eg. hot and windy conditions? • Waiting period  rapid return to service? • Chemical resistance eg chemical plants, industrial kitchens? • Floor design eg intricate patterns? ..... etc.

26. Selection Criteria  Choosing the Right Adhesive MS ISO 13007 Classifications

27. MS ISO 13007, Adhesive Specification Examples . Class ‘’C1’’: Where normal adhesion strengths are acceptable • Where to use? • Concrete & masonry surfaces • Other rigid surfaces • What types of tiles? • Ceramic & Glazed Tiles • C1: • Tensile adhesion strength of • 0.5 N/mm2 (72.5 psi) • at 28-d

28. MS ISO 13007, Adhesive Specification Examples Class ‘’C2’’: Where higher performance is required • Where to use? • Concrete & masonry surfaces • Other rigid surfaces • High-use areas • What types of tiles? • Porcelain tiles & low-absorbent tiles • Glass mosaics & larger formats • Natural stones • C2: • Tensile adhesion strength of • 1.0 N/mm2 (145 psi) • at 28-d • (compared to 0.5 N/mm2 for C1 adhesives) Airports, Malls

29. MS ISO 13007, Adhesive Specification Examples ‘’E’’: Extended open time • When would you use this? • With porous tiles or when the substrate is porous • Intricate laying patterns • Applications at higher temperatures • Applications in exposed windy conditions • (the mortar dries out more quickly) Intricate patterns • Class E: • Extended open-time. • Tensile adhesion strength of • 0.5 N /mm2 (72.5 psi) • with an open time of not less than 30 mins Applications in exposed conditions

30. ISO 13007, Adhesive Specification Examples The importance of using S1 & S2 deformable adhesives for suspended slabs • Slab deflection (curvature) • When the entire installation is subject to deformation due to loading, movement or deflection • S1 & S2 classications identify the correct adhesives to suit the deformation that will occur (within acceptable limits)

31. ISO 13007, Adhesive Specification Examples • S1 - Deformable • Required when installing large profile ceramic or porcelain tiles or stones over areas subject to movement • Areas subject to thermal stresses and expansion/contraction over time; deflection within acceptable limits where curvature is expected

32. MS ISO 13007, Adhesive Specification Examples • S2 - Highly Deformable • Exterior installations subject to high movements due to sharp temperature fluctuations and dynamic loading exterior facades • Suspended slabs; engineered wood-framed construction; multi-floor building facades

33. MS ISO 13007, Examples of Classified Adhesives These classifications must be displayed on the packaging, to provide the user with important information on the adhesive’s TESTED characteristics and performance properties

34. Other Necessary Requirements For A Quality Tiled Finish • Substrate preparation  flat, sound, clean • Workmanship to follow MS1294-Code of Practice for the design and installation for ceramic tiles and mosaics • Tiling Gap for wall tiles – Minimum 1.5mm • Tiling Gap for floor tiles-Minimum 3.00 mm • Protection of work

35. Problems With Tiling, Some Examples... Insufficient application of adhesive resulting in poor contact

36. Problems With Tiling, Some Examples... X Spreading the adhesive over too big an area (see next slide...)

37. Problems With Tiling, Some Examples... “Fresh” adhesive Adhesive is past open time. Result is weak/no adhesion X

38. Problems With Tiling, Some Examples... Hollowness; Air pockets beneath tiles causing one part to sound differently from another

39. Problems With Tiling, Some Examples... • Tenting of tiles. Possible causes are: • Absence of movement joints • Recommended movement joint • Internal – 5 to 7 meter • External -3 meter • Substrate movement / wrong adhesive selection

40. DE-BONDING OF PORCELAIN TILES (RESIDENTIAL)

41. DE-BONDING OF PORCELAIN TILES (SHOPPING MALL)

42. DE-BONDING OF PORCELAIN TILES (PUBLIC AREA)

43. DE-BONDING OF PORCELAIN TILES (EXTERNAL WALL)

44. No trace of any bonding materials on tile back – the tell tale sign of poor adhesion

45. INSTALLATION OF PORCELAIN TILES • IMPORTANT • 1. AVOID USING OPC – POOR BONDING AGENT FOR PORCELAIN TILES • 2. USE THE CORRECT TYPE OF ADHESIVE • 2. DO NOT ADULTERATE ADHESIVE WITH OPC • 3. AVOID MIXING LATEX OF DIFFERENT BRAND WITH ADHESIVE

46. LIPPAGE is a condition where one or more edge of the tile is not at the same level with the adjacent tile

47. LIPPAGE MAY BE CAUSED BY WORKMANSHIP OR BY WARPED TILES Lippage

48. LIPPAGE appears more prominently on LARGE FORMAT and RECTANGULAR TILES especially with rectified edges. Effect of tile lippage can be minimised by: • Ensure good preparation of substrate – flat and even • Use tiles with good planarity, e.g., polished tiles. • Minimise brick pattern installation for rectangular tiles • Install tiles following ‘arrow’ orientation • Allocate wider joint widths ANSI A137.1 recommends a minimum 4.5mm joint widths for large format tiles

49. RECTANGULAR TILES INSTALLED WITH BRICK PATTERN(50% OFFSET)

50. RECTANGULAR TILES INSTALLED WITH NOT MORE THAN 30% OFFSETTO REDUCE THE EFFECT OF LIPPAGE