DESIGNING WITH TILE

DESIGNING WITH TILE

ARIZONA CALIFORNIA COLORADO CONNECTICUT FLORIDA GEORGIA ILLINOIS MARYLAND MASSACHUSETTS NEW JERSEY NEW YORK PENNSYLVANIA TEXAS CANADA 1

DESIGNING WITH TILE

WHO WE ARE PORCELANOSA IS MANUFACTURER, DISTRIBUTOR AND RETAILER OF TILE, KITCHEN, BATH AND RELATED PRODUCTS

• A conglomerate of eight family owned companies under the Porcelanosa Group umbrella ♦ Porcelanosa ♦ Gama-Decor ♦ Venis ♦ Noken ♦ L’Antic Colonial ♦ Systempool ♦ Urbatek ♦ Butech

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Porcelanosa is a Registered Provider with The American Institute of Architects Continuing Education Systems. Credit earned on completion of this program will be reported to CES Records for AIA members. Certificates of Completion for non-AIA members are available on request. This program is registered with the AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product. Questions related to specific materials, methods, and services will be addressed at the conclusion of this presentation.

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COPYRIGHT MATERIALS This presentation is protected by US and International Copyright laws. Reproduction, distribution, display and use of the presentation without written permission of the speaker is prohibited. © PORCELANOSA USA 2014

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LEARNING OBJECTIVES At the end of this program, participants will be able to: 1.) Understand how tile is made and the different types of tile products available and the advantages they provide over other surface finishes 2.) Avoid problems with tile and stone installations by keeping in mind proper design considerations to select the right products for each application 3.) Know how to specify the correct materials and installation methods and products based on the building use, traffic, etc... 4.) Know how to utilize resources available for specification information and current standards

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DESIGNING WITH CERAMIC TILE

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OVERVIEW • Overview – 2 billion square feet a year in the US • Evolution – technology in manufacturing • Staffordshire/ Trenton / Modena / Valencia • USA – The Market 60% Floor /40% Wall • Consumers use floor tiles on the wall unnecessarily • Consumption per capita: 6 sq ft per head in the US - Spain 36 / Italy 26 / Canada 11 - Growth Potential in The US

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CERAMIC TILE - WHAT IS IT? Definition: Thin and very resistant flat slabs made from various compositions of clays and other inorganic raw materials. Composition:

Clay + Water + Fire (100% Natural Material)

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TILE BODY TYPES

Homogenous Through Body Porcelain Stoneware

Earthen Ware Gres Body with Glaze

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MANUFACTURING PROCESS (STEP 1)

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MANUFACTURING PROCESS (STEP 2) RAW MATERIALS • Ceramic tiles are made from natural materials, Ball Clay, Silica Sand, Talc, Calcium Carbonate, and Feldspar are some of the materials that might be mixed together to make ceramic and porcelain tiles. The top class manufactures search the world to bring in only the best raw materials for their products • Higher quality raw materials will assure a much better final product

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DESIGNING WITH TILE

FINE PORCELAIN STONEWARE CONSTITUENTS A Porcelain Tile will typically contain: • 40 to 50% Feldspar • 30 to 40% White Clays • 0 to 15% Quartz • 0 to 15% Kaolin and other fusible materials

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DESIGNING WITH TILE

MANUFACTURING PROCESS (STEP 3) GRINDING

SPRAY-DRYING

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MANUFACTURING PROCESS (STEP 4) PRESSING

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MANUFACTURING PROCESS (STEP 5) DECORATION

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MANUFACTURING PROCESS (STEP 6) FIRING

RECTIFYING

CLASSIFICATION, PACKAGING AND EXPEDITION 16

DESIGNING WITH TILE

CERAMIC TILE CLASSIFICATION (1) WATER ABSORPTION

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DESIGNING WITH TILE

CERAMIC TILE CLASSIFICATION (2) Tiles are classified based on their water absorption rate • ISO 10545-3 describes the standard test method for determining the percentage of water absorbed by the body of a ceramic tile, results are measured by the weight of water absorbed to the weight of dry tile • ASTM C-373 (equivalent ASTM method)

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DESIGNING WITH TILE

CERAMIC TILE CLASSIFICATION (3) WATER ABSORPTION RATES

• Non-vitreous (Low dense) WALL TILES - Tile with water absorption of more than 7.0 % - Suitable for interior WALL USE only - Lightweight and porous. Adheres very well to vertical surfaces • Vitreous (High Dense) FLOOR and WALL - Tile with water absorption of more than 0.5 percent, but not more than 3.0 percent. - Suitable for interior or exterior use • Impervious (Extremely dense) PORCELAIN - Tile with water absorption of 0.5 % or less. This is where porcelain tile is categorized - Interior and exterior use

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DESIGNING WITH TILE

CERAMIC TILE CLASSIFICATION (4) PORCELAIN VS. CERAMIC

• Is there a difference between porcelain tiles and ceramic tiles? Porcelain tiles are also ceramic tiles. Rather, the question should be, “What are the differences between porcelain tiles and non-porcelain tiles?” • What are the differences between porcelain tiles & non-porcelain tiles? Porcelain tiles are typically made with “porcelain” clays that have specific properties. Typically, these tiles are dense and by definition, they have water absorption of 0.5% or less. Non-porcelain tiles have water absorption greater than 0.5%. Because porcelain tiles have a low water absorption, they are usually frost resistant although, not always. To know if a tile is frost resistant, you should check the manufacturer’s recommendations.

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DESIGNING WITH TILE

WHY CERAMIC TILE? 1. Design versatility 2. Green product 3. Low Life Cycle Cost / Durability 4. Colors are permanent 5. Fire resistant

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1. DESIGN VERSATILITY It offers unparalleled design versatility ... • mono-chromatic colors • gloss or matte finishes • hand painted designs • smooth or rough textures • stone imitations • metallic or fabric textures • rustic looks • & many other variations and formats • ceramic mosaics

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WOOD PORCELAIN LOOK 23

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FABRIC LOOK 24

DESIGNING WITH TILE

MARBLE LOOK

MARBLE LOOK 25

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CONCRETE LOOK

DIMENSIONAL LOOK 26

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METALLIC LOOK 27

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CERAMIC MOSAIC 28

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MODULAR LOOK 29

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CONCRETE LOOK 30

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PORCELAIN TILE LAMINATE

PORCELAIN TILE LAMINATE

PORCELAIN TILE LAMINATE 31

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PORCELAIN TILE LAMINATE 32

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VENTILATED FACADES

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RAISED ACCESS FLOORING 34

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TILE FORMAT SCHEMATICS & LAYOUT CONSIDERATIONS

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JACK-ON-JACK

RUNNING BOND

DIAMOND

CHECKERBOARD

HERRINGBONE

BASKETWEAVE

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DESIGNING WITH TILE

BASKETWEAVE

BASKETWEAVE VERTICAL

OFFSET

ALTERNATING HORIZONTAL

BRICKWORK SQUARE

ALTERNATING

ESCALA

CORRIDOR

BRICKWORK VERTICAL

BRICKWORK VERTICAL NARROW

CORRIDOR HORIZONTAL

GRID HORIZONTAL

BASKETWEAVE HORIZONTAL

COBBLESTONE

HERRINGBONE

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VERTICAL LINE

HORIZONTAL LINE

RUNNING BOND PATTERN VERTICAL LINE

JACK-ON-JACK PATTERN

HORIZONTAL LINE

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2. GREEN PRODUCT Ceramic tile is environmentally friendly • Inhospitable to germs, bacteria & allergens • Production uses renewable, plentiful raw materials, recycles energy & does not create industrial refuse that burdens landfills • Faces of glazed ceramic tile will not retain liquids or absorb fumes, odors or smoke. It will not emit VOC’s thus allowing for good food, hygiene and increased air quality • Many types of tiles are recommended for environments where hygiene is essential. In fact, in Europe, ceramic tiles are required in public swimming pools, food processing plants and other critical installations



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95% RECYCLED CONTENT In keeping with its environmental commitment, Recycled Porcelain was developed, a tile collection manufactured with 95% recycled content from the company’s own production process.

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3. LOW LIFE CYCLE COSTS / DURABILITY (based on an independent study conducted and published by THE TILE COUNCIL OF NORTH AMERICA) Floor Finish Quarry Tile Glazed Ceramic Floor Tile Glazed Porcelain Mosaic Tile Unglazed Porcelain Natural Hardwood Travertine-Turkish Marble Laminate Man-Made Hardwood Portland Cement Terazzo Stained Concrete Carpet Resin Terrazzo Sheet Vinyl Poured Epoxy VCT

Installed Cost* $6.83 $7.00 $8.34 $8.20 $8.30 $9.31 $12.50 $21.00 $8.84 $9.58 $14.88 $12.40 $3.22 $8.50 $6.90 $8.18 $3.91

Life Cycle Cost* $16.13 $16.30 $17.64 $17.50 $17.60 $20.80 $21.80 $30.30 $17.77 $18.51 $24.27 $24.60 $6.50 $16.53 $13.90 $15.18 $18.35

Expected Life (years) 50 50 50 50 50 50 50 50 25 25 30 25 6 15 10 10 10

Cost Per Year* $0.32 $0.33 $0.35 $0.35 $0.35 $.042 $.044 $0.61 $0.71 $0.74 $0.81 $0.98 $1.08 $1.10 $1.39 $1.52 $1.83

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4. FIRE RESISTANT • Ceramic tiles are completely fire-proof at any temperature • Will not burn or feed a fire, nor will their surface give off any toxic gases or fumes

5. COLORS ARE PERMANENT • Ceramic tiles will never be affected by UV Rays. They present an excellent solution for exterior facades in buildings

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TILE IS NON COMBUSTIBLE • It will not emit noxious fumes • It cannot be damaged by cigarette butts

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IMPACT RESISTANCE • Porcelain tile has the highest resistance to impact damage • A major factor is the solidity of the underlying substrate. The surface is dependant on a structurally sound surface and bedding method

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EXTREMES OF TEMPERATURE • Porcelain tile has the best characteristics to cope with extreme temperature changes

Thermal Shock

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CHEMICAL RESISTANCE • Tile is highly resistant to acid and alkaline attack • The optimum specification for  Hygiene critical areas inc.  Fast food outlets  Breweries  Dairies • It will not harbor germs and can be easily disinfected without damage

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SPECIFICATION CONSIDERATIONS (1) • Ceramic tiles are one of the strongest and most durable surface finishes available • By following some basic specification considerations we can make sure we are choosing the right product for each application and achieve a long lasting installation

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INSTALLATION OPERATIONS

PREPARATION OF THE SUPPORT SURFACE

PREPARATION OF THE BINDER

APPLICATION OF THE BINDER, I.E. PREPARATION OF THE TILE BED

SETTING THE TILE

SEALING THE JOINTS

CLEANING

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SPECIFICATION CONSIDERATIONS (2) • The right type of tile for the each application • Traffic pattern / wall or floor • Reliable manufacturers will always provide technical information that will help you determine the appropriate use for each tile SUCH AS:

Identifier 1 2 3 4 5 6 7

Type of Use Wall only Floor with low pedestrian traffic Floor with moderate pedestrian traffic Floor with medium pedestrian traffic Floor with high pedestrian traffic Floor with very high pedestrian traffic Floor with heavy or vehicular traffic

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SPECIFICATION CONSIDERATIONS (3) Review tests results from manufacturer’s specification sheet for: • Interior or Exterior application • Water Absorption: This will determine whether the tile can be installed in an exterior application or interior only • Coefficient of Friction: This will determine the suitability of the tile to be installed in an exterior application or an area subject to pedestrian traffic and presence of water or other liquids. • Frost resistance: This result will determine if a tile will withstand a freeze/thaw cycle in a harsh climate

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SPECIFICATION CONSIDERATIONS (4) COF – Static Coefficient of Friction (Old Method) • ASTM – 1028 describes the standard used to determine the slip-resistance of a tile. BUT not mandated by any industry body including ADA • According to the ADA American Disabilities Act; accessible horizontal routes should have a minimum static COF of .6 whereas ramps should have a COF of .8

OLD TEST

Pull-meter Meter is placed on a dry or wet tile. the meter is then pulled until it breaks free or slides across the tile giving a measurable COF of the tile

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TCNA: NEW METHOD FOR MEASURING DCOF • Dynamic coefficient of friction (DCOF) is the new gold standard for defining acceptable coefficient of friction measurements. The DCOF AcuTestSM method will soon replace ASTM C1028 as the specified method for coefficient of friction (COF) testing. DCOF AcuTest is a more repeatable method offering a better indication of actual slip potential on a tile surface • This new method uses the BOT 3000 automated portable testing device with a specific type of rubber sensor and slightly soapy water. The sensor is resurfaced using a sanding device designed by the TCNA’s Product Performance Testing Laboratory • A new version of ANSI A137.1 has been published with the new DCOF AcuTest method. Additionally, for the first time there is a minimum COF requirement of 0.42 for level interior tile surfaces expected to be walked upon when wet, compared to the old .60 SCOF (static coefficient of friction) wet measurement

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TILE COUNCIL OF NORTH AMERICA MODERN INSTALLATION METHODS

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PROPER INSTALLATION MATERIALS (1) THIN-SET Modified vs. Non-Modified Again, the water absorption of the tile will determine if you should use a modified or a non-modifed mortar. Porcelain tiles (less than 0.5% of water absorption) will always have to be installed with a modified mortar. It is the latex additive which allows the chemical bonding with a virtually impervious body. A higher absorption body tile type creates an easier mortar bonding by penetrating the ceramic body (wall tiles on a vertical application)

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CORRECT ADHESIVE SPECIFICATION ANSI A118.1 • Porcelain tile cannot be adequately set in non modified cement sand adhesive mortars • The impervious body requires adhesion from special bonding agents often referred to as “Polymer Modified Adhesives” • The Polymer may be generically known as Latex and may be a synthetic latex or Acrylic. It can often be applied as a liquid to standard adhesive mortar or is commonly found pre mixed within a single part adhesive which prevents incorrect gauging at the job site

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ADHESION FAILURE • Tile failure is most often attributed to incorrect usage / specification of installation material rather than faulty product

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HIGHEST QUALITY PORCELAIN MAY TYPICALLY HAVE POROSITY LEVELS AROUND... 0.1 = 5 x lower than standard

0.02 = 25 x lower than standard

5 x more difficult to bond

25 x more difficult to bond

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SURFACE REGULARITY FLATNESS OF TILED FINISH • To achieve a level surface without lippage the substrate should be accurate to within1/8”under a 6’ straight edge (3mm under 2m) • There are accessories on the market to ensure proper installation

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PROPER INSTALLATION MATERIALS (2) When the use of MEMBRANES makes sense: Waterproofing: in a typical shower tile installation there can be problems over time created by moisture and water penetrating the wall and floor cavities. This factor can produce serious damage to the installation and is the major cause of mold growth. The use of a single ply waterproofing membrane minimizes the possibility of damaging leaks and mold growth due to moisture penetration Uncoupling (crack isolation): These membranes are specially recommended for outdoors applications. They serve as an uncoupling layer, waterproofing membrane, and vapor management layer that accommodates moisture from beneath the tile covering. They effectively neutralize the differential movement stresses between the substrate and the tile, thus minimizing the major cause of cracking and delaminating of the tiled surface

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WATERPROOFING MEMBRANE

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WATERPROOFING Tile is always the best choice wall and floor finish in Bathroom areas and is not affected by water / water vapor, steam or humidity. HOWEVER…… Substrate Preparation is essential to ensure that moisture ingress does not cause progressive damage. Specify: • Waterproof Backer Boards • Treat drywall with Waterproof Membranes • Use Mould Inhibiting Grouts • Specify Water Resistant Adhesives

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UNCOUPLING (CRACK ISOLATION) MEMBRANE

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PROPER INSTALLATION MATERIALS (3)

Grouts Grout is usually a cement-based material used to fill in the spaces between the tiles. There are different types of grouts. Sanded • One of the most common grout used for ceramic tile, stone, and any tile with a grout joint 1/8” or larger • Made of Portland cement, sand, and other additives • When installed, it is mixed with water and toweled into the grout joint • Takes approximately 24 hours for the grout to dry Non-sanded/ Un-sanded • Similar to sanded grout without the sand • Used on ceramic tiles and stones, with grout joints smaller than 1/8”

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Latex modified • Almost exactly the same as the other grouts • Latex polymer is either incorporated into the pre-mixed powder or added during mixing • This grout has increased water resistance and bonding characteristics Epoxy • 100% epoxy • No water is present in the mixture, clean up is still accomplished with water • Consists of epoxy resin, silica fillers, pigments, and a hardener • Resistant to staining • Very low water absorption • Higher compressive strength than concrete • Highly resistant to chemical attack

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SELECTING THE RIGHT METHODS Reference Standards • Tile Council of North America (TCNA) Handbook for Tile Installation - industry guidelines and specific installation types • Amercian National Standards Institute, Inc. (ANSI) - information on installation and testing methods and product performance requirements - A118 – Materials - A108 – Installation Methods • Marble Institute of America (MIA) - information on natural stone and their installation methods - Dimensional Stone - Design Manual • Manufacturer’s Recommendations - product information, installation instructions, and material safety through data sheets and MSDS

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THANK YOU FOR YOUR TIME.

ANY QUESTIONS?

This concludes The American Institute of Architects Continuing Education Systems Program 66