Porcelain

 

Good quality porcelain is undoubtedly the most maintenance-free flooring material available.  There is a broad range of types of porcelain based on the various manufacturing processes, with varying surface textures, glazes and porosity.  Surface texture that replicates stone or other textured effects is applied with presses prior to firing of the tile.  Production processes that utilize a number of different presses or combinations of presses create the most random and hence natural looking tiles.  

Through-body porcelain is manufactured as one monolithic tile without surface glazes or finishes and is characterized by the colour pigments being consistent throughout the body of the tile.  Originally, the aesthetic look was limited to speckled, ‘salt & pepper’ effects.  More recent developments in the production process have made it possible to mix together various colour pigments so that random swirls and veins of colour, similar to natural effects, can be produced.  

Double-pressed porcelain is manufactured with two layers of porcelain pressed together and then fired.  The top layer is approximately 1mm thick and is pressed to the base porcelain layer under high pressure.  This top layer is comprised of porcelain clays randomly infused with various colour pigments that create an infinite range of colour combinations and patterns and hence can approach the variety of natural stones.  This bonded porcelain ‘sandwich’ is then fired.

Another method of creating random colour and shading characteristics is to apply soluble chemical salts to a through-body porcelain bisque prior to firing.  Applied using multiple silk screens, spray machines or brushes, the overall aesthetic effect can be quite varied.  Suspended in an aqueous solution, these metal salts penetrate into the unfired tile body.  After the tile body dries, the tile is fired during which time the metal oxide salts react with the porcelain body resulting in various colours.   This type of porcelain is considered unglazed since the salts are not a monolithic glaze.

Recently, the technology for producing glazed porcelain has come into wider use.  This is not dissimilar to glazed ceramics in that there is a full colour spectrum available.  However, there are many advantages over a glazed ceramic: i) porcelain is a higher quality clay than ceramic, ii) the porcelain particle size is extremely fine, iii) the tile is pressed under very high pressure, iv) porcelain is fired at a higher temperature for a longer period of time.  The resulting tile and glaze are harder and more wear-resistant.  Glazed porcelain has the lowest surface absorption of all porcelain because of the glass-like vitrified finish to the tile.

 

Installation

Porcelain tile must be installed over sound, level, fully cured concrete, masonry, cement board or other approved surfaces.  A premium floor and wall dry-set mortar should be used with a latex additive. 

Grout line dimensions are an aesthetic consideration but sufficient width should be allowed for proper application of the grout (use sanded grout for floors) and to allow for dimensional tolerances in the tile.

Particularly important with respect to light coloured or textured tiles, is to clean the floor after installation with Grout and Concrete Film Remover to ensure that there is no grout residue on the surface of the tile that will attract dirt and stain.

Although high quality porcelain has an absorption rate of less than 0.03%, some porcelains can range, by standard, up to a maximum of 0.05%.  These, as well as high-density porcelain with an open grit, anti-slip surface, should be sealed with a good quality penetrating sealer, such as 511 Porous Plus, before and after grouting for ease of maintenance and to ensure a level of stain resistance.  Even if the tile need not be sealed, the grout lines may be sealed if a light colour grout is used and ease of maintenance and stain resistance is desired. 

 

Maintenance

To maintain a porcelain installation, reasonably frequent washing is required with clean water and very little good quality neutral or alkaline detergent such as Mira Clean #1.  The amount of dirty water left standing on the tile should be minimized.  Porcelain tile does not require waxing.  Periodic resealing may be recommended.

For heavier cleaning requirements, wash with Porcelain & Ceramic Tile Cleaner or Tri-Sodium Phosphate.  Mix 1 cup of powdered TSP to 3 gallons warm water.  Wash with a powdered brush scrubber and rinse with a hydro-jet and water.  Re-seal the floor if required.

Porcelain may become dull from cleaning with dirty water since, and, over a period of time, water will soak into even extremely low porosity material.  In order to restore the tile, apply Grout and Concrete Film Remover, diluted with water at a ratio of 1:5.  Apply liberally and allow to stand for a few minutes, agitating with a stiff brush.  Wet vacuum to remove the liquid.  For cleaning of deep stains, Liquid Poultice should be used.  It is a biodegradable, non-acidic, deep cleaner designed to penetrate deep into the pores of the tile to safely lift out mold, mildew, algae, fungus, coffee, tea and other types of foreign matter.