An ‘Expanded’ Look into Large Format Tile
by Bill Griese
December 9, 2008
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The use of large
format tile can contribute to a minimalistic “monolithic envelope” look that is
gaining popularity.
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Tile Q & A
This article, the first of a two-part series pertaining to
large format tile, will provide the background behind large format tile, and
discuss the science behind the “trendy” and increasingly popular use of such
products. In part two, we will discuss installation and the extra precautions
that consumers should consider when dealing with large format tile.
How large is large?
Currently, a specific definition for “large format tile”
does not exist. In the tile industry, the term “large format” has evolved over
the last several decades. There was a time when 4”x4” tiles were considered
large. Soon thereafter, 8”x8” tiles were considered large. In fact, the current
2008 TCA Handbook for Ceramic Tile Installation includes the statement, “Large
tiles are generally considered to be 8”x8” and greater.” While this is valid
from an installation perspective, with the regularity that 12x12’s are used
today, most would not consider 8”x8” to be very “large.” Tiles as large as
24”x48” are becoming common. Some manufacturers are even producing tiles
measuring up to 1x3 meters! But generally, most would consider large format
tiles to be 18”x18” and larger.
How are manufacturers able to produce such large tiles?
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Large format tiles
can open up small residential spaces, such as this condominium kitchen, making
them seem larger.
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Today, manufacturers possess a wealth of technological
advances that allow for ceramic tiles to be produced larger and larger.
Beginning with raw materials,
improvements in organic binders and advances in spray drying technology
resulted in sturdier green body (unfired) tiles with more evenly distributed
densities.
Pressing technology also improved.
As tiles get larger, presses must get stronger to achieve the die pressures
necessary for producing large format tile. Some manufacturers have presses with
capacities as high as 7,000 tons. Advancements in large format isostatic dies
also aided pressing technology.
Large format tiles provide a larger
design “canvas,” and the opportunity for glaze patterns and designs to be big,
detailed, and continuous. Designs of high resolution can be transferred onto
larger surfaces and fired to achieve commercial-grade durability. With the use
of automated and highly precise equipment, uniform temperatures throughout very
large kilns can be achieved to aid in firing accuracy and shrinkage management.
Finally, tile rectification assists
in the dimensional accuracy of large format tiles. By mechanically finishing
all four sides, manufacturers can produce very large tiles within tight targets
for facial dimensions. This eliminates the need for multiple calibers.
In addition to traditional tile
forming processes, some manufacturers are incorporating innovative practices
that allow for tile sizes to increase facially, but decrease in thickness. In
some cases, these very large but thin tiles are reinforced with fiberglass mesh
backings to maintain high breaking strengths.
Why are large format tiles so popular these days?
With the increasing amount of manufacturers able to produce
large format tiles, there is an expanding market. According to a 2007 survey of
manufacturers producing 18”x18” and larger tiles, such tiles made up
approximately one-third of their sales. According to a survey of distributors
that same year, sales of tiles 18”x18” and larger were 35- to 40-percent of
their business and trending upwards. Without a doubt, large format tiles are in
style, and continue to increase in popularity. But why? There are a multitude
of reasons.
For one, the use of large format
tiles results in less grout overall. Having less grout generally appears
“neater,” and can make cleaning -up and maintenance easier. Furthermore, with
rectified large format tiles, where the edges are only slightly beveled or not
beveled at all, the use of such tiles creates the perception of a narrower
joint, less grout, and a generally “flusher” look. However, as we will discuss
in the second article, this look can only be achieved if the appropriate
installation practices are followed. If these practices are ignored, the
installation of non-beveled edge large format tile, especially with a narrow
joint, can be highly problematic.
Designers often enjoy using large
format tiles in situations where the same type of tile on the floor is used to
cover surrounding walls and/or ceilings. This “European” minimalist style,
sometimes referred to as a “monolithic envelope,” is becoming increasingly
popular.
The use of large format tiles can
also make average-sized rooms appear larger and bring proportionality to large
commercial spaces.
For exterior applications, large format tiles are becoming
more popular for use on building façades. When used in conjunction with
cladding systems, exterior tile façades create an air pocket that evacuates
warm air in the summer, and keeps insulation dry in the winter. This effective
thermal barrier is an energy efficient exterior option, though its use is not
widespread in the U.S. But regardless
of whether or not large format tiles are used on building exteriors in this
way, more and more architects and designers are considering large format tiles
an attractive exterior option.
What should customers expect with large format tile Installations?
In many cases, large format tiles are inappropriately
specified as if they were natural stone. Customers need to know that tile and
stone each has unique advantages and drawbacks, and each requires different
installation practices. In the next series, we will discuss the steps that should
be taken when installing large format tile.
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