Cladding with clinker tiles is a well-known way to improve a fireplace or stove. This tile has many textures, colors, shades. Particularly popular are tiles that imitate brick. It is characterized by great strength and service life.

Not all types of clinker tiles are suitable for facing a fireplace. When choosing a specific material, you need to take into account a number of nuances.

What is taken into account when choosing clinker?

The main factor that most people pay attention to is appearance. From a professional point of view, this factor is not the main one. First of all, you need to look at the expansion coefficient. In order for tiles to remain in place for decades, they must expand when heated, much like fireplace walls.

Preparation method

The expansion coefficient of clinker directly depends on the production method. Thus, classic tiles used in facade cladding are distinguished by their high density and water resistance. These qualities make it ideal for use in cold weather, but prevent expansion when heated.

Dense clinker tiles are made using the extrusion method. First, the clay mixture passes through specialized molding nozzles, after which the resulting semi-finished products are dried and baked under high temperatures.

Another method of making tiles is semi-dry molding. The clay paste is pressed into special molds and then baked at high temperature. Drying is excluded with this method. The resulting tile is more porous and has less frost resistance. It is not recommended to be used for cladding facades, but it is ideal for decorative finishing of fireplaces. The expansion coefficient of this tile is similar to brick.

The reverse side of extruded and molded clinker differs in relief. A relief mesh is applied to the molded clinker tiles. Small longitudinal grooves are easily visible on extruded clinker.

An example of clinker tiles for fireplaces is.

What clinker should I use for finishing stoves and fireplaces?

Many European factories produce exclusively extrusive clinker. In some factories, molding clinker is produced manually. In its production, standard semi-dry molding is used, due to which it acquires heat-resistant properties. Thanks to manual molding, each individual tile acquires its own unique appearance and relief.

Clinker tiles are used exclusively for exterior decoration. If it is necessary to treat the inside of the fireplace, fireclay bricks or other refractory material are suitable for this.

If the fireplace requires high-quality thermal insulation and the heat does not pass through the walls, you can use any clinker tiles for decorative finishing.

Features of clinker finishing

A fireplace lined with clinker tiles will heat up less and take longer to cool down. This is due to the characteristics of the material: low thermal conductivity prevents heat from escaping outside, high thermal capacity prevents the tile from cooling after the fireplace goes out.

This feature is important when using the fireplace regularly. If it serves for decorative purposes, this property is not critical.

Contact us

We offer various types of clinker tiles for facing fireplaces and stoves. You can get detailed advice on the technical characteristics of the material from our specialists. To get a consultation, just leave us your phone number, and they will call you back soon.

Clinker tiles and brick - the most durable, reliable, status, prestigious solution for finishing the facade of a country house or administrative building. It is worth recognizing right away that clinker is far from the cheapest option, however it will not only increase the market value of your home, but will also give you a feeling that is difficult to measure in money. confidence, prosperity And superiority that will stay with you forever.

Pressed or extruded tiles?

By entering the query “clinker tiles” or “clinker facade” into Google or Yandex, you will receive more than 100,000 articles and proposals where you will be offered clinker facades of Polish, Russian, Belgian, German and even Belarusian production. and so as not to get lost in these proposals, we suggest you understand the issue once and for all:

What is hidden behind the phrases “clinker”, “clinker facade” and “clinker tiles”?

Essentially the word CLINKER- this is a derivative of the description of the characteristics of brick, which came to us from the Middle Ages. It appeared from the word KLINK, which describes the ringing sound emanating from a burnt brick after being struck. For builders, before the era of certificates and technical tests, this sound was one of the few criteria for assessing the quality of the material from which walls were laid. The louder a brick sings, the higher its strength, the fewer impurities it contains and the greater the load it can withstand. This is where the derivative KLINKER comes from – a sign of reliability, durability, and high quality.

Now, in the era of technological progress, measurement accuracy, precise regulation of production processes and the use of building and finishing materials, the word CLINKER has become more of a beautiful marketing story accompanying completely different building materials. And in order to choose a reliable and durable material for cladding the facade, it is not enough to hit two tiles against each other. You need to dig a little into production technologies. manufacturers and sellers of facade materials Clinker is any facing tile that has the appearance of a brick.

That is why we need to figure out what technology for the production of facade tiles guarantees us the durability and status of that very “Clinker”

The dilemma is whether to prefer only aesthetic aspects or to take into account technical ones as well. At the moment, there are two technologies for the production of ceramic facades: And cold pressing.

They differ both in production method and in functions, which have a direct impact on cost and efficiency of use. Some of them have, for example, smaller tolerances, others are more resistant to adverse weather conditions. By providing this information, we hope that the investor will be able to make informed decisions, taking into account not only their own preferences and expectations, but also technical aspects in order to enjoy the end result of beautiful and durable facades for many years.

Ceramic facade tiles can be produced using two technologies:

1. Technology extruded clinker.

This is a traditional technology used in the production of clinker, bricks and cobblestones.

Blanks made from plastic masses of refractory purified clay with a moisture content of 15 to 30% are passed through an extruder, which, without creating supernatural pressure and without disturbing the molecular structure of the raw material, gives future tiles or bricks a geometric shape. Then the raw workpiece is cut into individual products, and decorative elements are applied using soot mixtures and natural pigments. After which the blanks enter a tunnel kiln and are fired for 48 hours at a temperature of 1300 degrees C. Firing gives the final shape, creating porosity sufficient for vapor permeability and burning out all kinds of organic impurities from the structure of the raw material.

The output, after mandatory two-stage quality control, is extruded clinker tiles. clinker with a unique front surface created by the elements of fire, water and earth. Each extruded tile is unique. And there is nothing more to say about the strength of the material fired at extremely high temperatures.

2. Semi-dry pressed clinker.

The tiles are produced using the semi-dry pressing method. When pressing, a powdery mass with a moisture content of 4 - 6% is compressed in two directions, usually under a pressure of about 200-400 kg/cm2. Under pressure, the granules move and partially deform, due to which the unfired tile acquires the strength necessary for subsequent operations. During the pressing process, the molecular structure is compressed, reducing the pores that discharge steam and creating additional internal stress in each individual tile.

What is affected by the difference in technological processes?

if we ignore the aesthetic features of the appearance of tiles made using pattern pressing and natural firing methods

At this stage, we can identify 2 fundamental differences between extruded clinker and semi-dry pressed facade tiles

1. Adhesion. Ability to set and hold time on adhesive solutions when performing outdoor work

Semi-dry pressed tiles pressed against a dry, almost glassy and smooth surface without any open micropores formed after aggressive pressing. The glue is not able to penetrate deep into the structure of the plate. This, of course, limits the possibilities of bonding with the adhesive solution and specialized adhesive mixtures are required to obtain sufficient bond strength. Especially when the tiles are used outdoors: not only in the cold in winter, but also in summer - the sun and large daily temperature fluctuations can lead to separation of the tiles from the substrate (load-bearing wall).

Surface of pressed tiles, magnified

In case they have a porous and rough structure, which provides a large contact surface for the adhesive mortar. The glue easily and deeply penetrates the micropores of the open system, which leads to special strength of the glued tiles.

Magnified surface of extruded tiles

2. Vapor permeability. The ability to quickly remove wet vapors from the façade during natural and extreme temperature changes

They have low water absorption, so they may seem more stable and durable. The reality is completely different. It is worth considering the internal structure of two materials that have a direct impact on the performance and ease of use of the stove. In the technology of producing a dry compressed body of tiles with a structure of compressed chaotic material particles, between which the micropores are closed with very thin capillary channels. This results in low water absorption and also very slow water flow. It is assumed that no water has entered such products. However, this assumption is purely theoretical. The water remaining in the tiles, due to the closed structure and compacted material, cannot be removed and this will lead to expansion when freezing in the cold. Consequently, this may cause damage to the tiles. Additional risks of moisture escaping from glued tiles. Dry pressed boards do not have the ability to remove water outside the substrate. Water partially enters the tile and, remaining under it, can weaken the bond with the substrate, the supporting frame.

Structure and behavior of water in pressed tiles

Facade clinker Structure and behavior of water in.

The internal structure of tiles obtained using extrusion technology is completely different. During the extrusion production process, the microstructure is not damaged and retains its natural, homogeneous character. A network of interconnected capillary channels makes it possible to quickly remove moisture; they have less absorption capacity than, but the water easily flows back into the environment. The microporous structure makes the facade tiles resistant to freezing of water remaining in the tiles. In addition, due to its structure, tiles made using extrusion technology easily get rid of water between the tile and the adhesive layer, which prevents the possibility of its accumulation in the tile area. Thus, extruded tiles have higher adhesion to the base and, accordingly, the tiles are less likely to come off the base. There is less water absorption due to the internal structure, the tiles are more durable and more resistant to extreme weather conditions.

Structure and behavior of water in extruded tiles

Facade tiles. Aesthetics.

As already mentioned, the aesthetics of the tiles are pressed and completely different. Of course, there is no way to say which one is better, because both groups have their supporters and opponents. For some, the smooth, repeating surface of pressed tiles from element to element has a plastic, artificial appearance; for others, the surface is too “strict”. Pressed products are produced in molds so that the structure of the model is repeatable and their surface is highly reproducible. They are characterized by greater accuracy than extruded, fired products, and have smaller tolerances and color. The surface is very smooth, often covered with engobe, therefore, it is a stretch to say that they are artificial, plastic, and only the size resembles a brick. The pressed plates have a thickness of 6-7mm and, therefore, the small space between the tiles and the base is filled with a fugue (joint filler), which reduces the water resistance of the wall. The structure of such joints in pressed tiles is smooth and unlike the joints used in a brick facade.

When gluing pressed tiles, the tile cannot be pressed too hard to create a successful brick look. Thin mortar is also less durable and, as a result of wind due to air suction, can crack and crumble.

Clinker is made in exactly the same way as clinker bricks, from the same raw materials and using the same technology. So the surface looks similar to that of traditional clinker products. They are not as smooth as pressed tiles, they also have higher frost resistance. They are so perfect that after covering the facade, no one can say whether it was faced with tiles or bricks. The range of products produced using extrusion technology is rich in natural colors and surface structures, like clinker bricks. Often, façade tile manufacturers will offer the same or similar tile and brick colors needed to complete associated features such as facades, chimneys, fences and landscaping. Due to the fact that they are produced in thicknesses of 9-14mm, they can use the same grouts as for sealing joints for bricks, therefore, their particle size and structures are identical to the surface of masonry mortars. We hope that based on the above information, the investor, considering the technical and aesthetic aspects, will be able to make informed decisions and have tiled walls with trouble-free operation.

21.04.2014

Contents:

Clinker brick is a variety. Clinker differs from ordinary ceramic bricks in its high density and structure, which is determined by specific production technology. Such a brick is fired until the shard is completely sintered.

History of clinker bricks

Clinker first appeared in Denmark, in the city of Bockhorn in 1743. A workshop was opened there for firing bricks, which were used for building roads. Deep firing made the brick as strong as cobblestone, but unlike cobblestone it was easy to lay. However, the point is not the ease of installation: there was simply not enough building stone in Denmark, and it was expensive to import it from afar.

Clinker production in Russia began in 1884 in the village of Topchievka, Chernigov province. The Topchievsky plant used screw presses and a German Hoffmann furnace. At the same time, the plant did not produce bricks, but crushed ceramic stone: first, all the clay was sintered into a single mass, and then the resulting layer was split into pieces and used for road work.

In 1904, the plant switched to the production of full-fledged clinker bricks, and in 1908 the ring Hoffmann kiln was replaced by a chamber kiln. This sharply reduced the yield of underburned bricks: if previously the share of underburned bricks exceeded half of the total volume, then after installing a chamber kiln its share decreased to approximately 25%.

There were several factories producing clinker bricks in the USSR, but their total production capacity was insignificant. The factories produced bricks for road construction and furnace masonry.

Clinker brick production technology

Clay selection

For the production of clinker bricks, refractory clays with a high content of aluminum oxide are used. Aluminum oxide (Al2O3) reduces the viscosity of the melt and reduces the deformation of bricks during firing. The optimal Al2O3 content is 17…23%. Clays with low aluminum oxide content are further enriched by adding kaolinite clays to the mixture.

Clays always contain some amount of iron oxides - trivalent and divalent. The iron content determines the color of the brick, which varies from cherry red to dark purple.

The content of ferric iron (iron oxide Fe2O3) in clay should not exceed 8%. This is due to the fact that when exposed to temperatures of about 1000 degrees under the conditions of a kiln, Fe2O3 is reduced to FeO, which reacts with silicon oxide, forming Fe2SiO4 (fayalite). Fayalite forms a crust on the surface of the brick, which prevents the oxidation of carbon and the removal of carbon dioxide. Unburnt carbon can form blisters on the surface of clinker bricks. This problem can be solved by reducing the heating rate of the raw material in the range from 900 to 1100 degrees.

• reducing the sintering interval of clay (at first the clay is slowly sintered, giving slight shrinkage or expansion, and then sudden melting occurs, the formation of a liquid phase and deformation of the brick under the influence of its own weight and the weight of the bricks lying on top);
• increasing brick porosity. Carbon dioxide formed during the thermal decomposition of CaCO3 (this salt is always present if there is calcium oxide) expands and forms pores.

Silica module

Silica modulus is a value characterizing the ratio of the proportion of silicon oxide to the total content of aluminum oxide and iron oxide. Calculated using the formula:

Clays with a silica module of 3...4.5 are suitable for the production of clinker bricks. Clays with a low index have a narrow range of sintering temperatures, which significantly complicates production. Clay with a high silica modulus produces brittle brick.

Extrusion technology for the production of clinker bricks

The essence of the technology is simple: thoroughly mixed clay is squeezed out of the extruder through a hole with a certain cross-section. All that remains is to cut the tape into individual bricks and send them for firing. The line can be supplemented with a press.

The extrusion method makes it possible to obtain bricks of the highest quality, but the energy consumption for producing a unit of brick is quite high. This method is widely used by many well-known European manufacturers. In Russia there are several factories that produce clinker using the extrusion method; in Ukraine (at least until recently) there was only one - “Kerameya” in the Sumy region.

Semi-dry pressing

Semi-dry pressing makes it possible to produce clinker with minimal energy consumption, but its density and mechanical strength will be lower. In plastic pressing, dried and crushed clay is placed into molds where it is pressed. After this, the future brick is dried at a temperature of approximately 80 degrees. Drying duration is 24-45 hours.

Firing clinker bricks

Regardless of the clinker production technology used, the final stage of its production is firing. Most often, continuous firing tunnel kilns are used for this purpose. The length of such kilns can exceed 200 meters: moving using a conveyor belt, the brick passes through zones with different heating temperatures. The maximum temperature ranges from 1100 to 1450 degrees. At this temperature, the clay is completely sintered and turns into a monolithic ceramic shard.

GOST

Currently, GOST for clinker bricks is being developed. Factories produce it according to their own specifications, which, in turn, are based on DIN V 105 -100, DIN EN 771-1 and DIN EN 1344.

Types of clinker bricks

• full-bodied - has no voids. Characterized by high density, strength and thermal conductivity;
• hollow - has voids that reduce heat loss from the brick;

By purpose:

• facing clinker bricks are used for finishing buildings;
• road clinker brick - used in road construction;
• stove clinker brick - used for the construction of stoves, fireplaces and chimneys.

Separately, there are shaped clinker bricks, which can have different shapes. It is used for finishing and construction of decorative structures (gazebos, flower beds, columns, fencing, etc.).

Advantages and disadvantages

Advantages (pros) of clinker bricks:

• very high mechanical strength;
• very high frost resistance;
• durability;
• attractive appearance.

Disadvantages (cons) of clinker bricks:

• high density - requires a powerful foundation, complicates transportation, etc.
• high thermal conductivity - increases heat loss;
• high price.

Ceramic clinker tiles are a building material that has been produced for several centuries. Today, as before, it remains popular and is used everywhere: it is used to line the steps of cottages and public buildings, floors, walls, fireplace portals, and swimming pools. Recently, the production of thermal panels lined with clinker tiles has been launched. This material is practically indistinguishable in appearance from high-quality brickwork.

It is produced in different textures: with a rough (matte) surface and glossy. The color palette is also very different: from dark brown to light ocher or yellow. The surface of the material can be covered with glaze. Dimensions of standard tiles are 245x66x8mm.

The color palette is quite varied from dark brown to light ocher or yellow.

From the origin story

The founders of the production of clinker tiles were the Dutch, who were forced to use “sea” clay to produce this type of artificial stone due to the lack of natural material. This happened at the beginning of the 19th century.

At first, roads were paved with this artificial stone, but then they began to clad the facades of buildings with it.

Subsequently, the Poles picked up the baton: they learned to produce very high-quality and inexpensive tiles, which they began to export to many European countries. We have also established production, but, unfortunately, the quality of domestic material is still inferior to foreign samples.

Tiles of various shapes, for example, concave, convex or even in the form of an angle, can be made using the extrusion method, which you can read about below.

Some information about production

The process begins with mixing different types of clay with the addition of fireclay, feldspar, quartz sand and broken earthenware. The resulting mixture is ground and crushed to a homogeneous mass using special mills. The next stage is drying. The result is a granular substance needed as a raw material. The tiles are formed either by pressing or by extrusion.

The pressing process involves filling the mass into special forms, compacting it and pressing it with high pressure. Extrusion occurs with the addition of water and mixing of the raw materials until a dough-like mass is obtained. The resulting mass is passed through a special hole, the dimensions of which correspond to the dimensions of the finished product. The emerging strip-blank is cut to length.

The color of unglazed tiles depends on the porosity of the clay and its iron content. Clinker products undergo a much longer firing procedure and at a higher temperature than regular tiles: 1.5 days at 1500 °C.

During firing, the main qualities inherent to this material are formed: high density (due to complete sintering of the clay), resistance to mechanical damage, temperature changes and abrasion. Its water absorption is 5 times less than that of ordinary tiles: this ensures high frost resistance.

Features of different manufacturing methods

Each of the above methods has its own advantages and disadvantages. Pressing makes it possible to obtain clinker tiles with more accurate dimensions and high surface quality. However, the extrusion method requires lower financial costs, which means products obtained in this way are cheaper. In addition, extrusion allows you to produce (unlike the pressing method) tiles of various shapes, for example, concave, convex or even in the form of an angle. Another feature of the extrusion method is that the resulting product has conical grooves that improve adhesion to the base.

Material advantages

Clinker tiles have a number of advantages over conventional ceramic tiles, namely:

• it is more wear-resistant;
• has greater strength;
• it has a longer service life;
• due to high frost resistance, it can be used for outdoor work;
• has a low level of moisture absorption.

This finishing material received such characteristics due to the peculiarities of production technology. During the firing process, a top layer is formed that performs a protective function: thanks to this, the tile does not become dirty, does not change its color and is easy to clean with any chemical or even abrasive agent.

What are ceramic tiles and what are they made from?

Ceramic tiles are slabs of baked clay. Most often they come in square and rectangular shapes, but can be made in the form of a complex geometric mosaic. It can be used to decorate walls and floors both indoors and outdoors.

1. Wear resistance is one of the most important qualities of floor tiles, which characterizes the tile’s resistance to abrasion and its ability to maintain its appearance without changes. There is a PEI classification that includes five groups: PEI I - for walls in bathrooms, PEI II - for walls/floors in bedrooms, offices, bathrooms, PEI III is installed in any residential premises and in small offices that do not have a direct entrance from streets, PEI IV is suitable for any living rooms, as well as for covering stairs, halls, corridors, PEI V is used in both private and public interiors with above average traffic (offices, shops, cafes, restaurants). For places with heavy traffic (traffic), it is recommended to use unglazed porcelain tiles (airports, train stations, shopping centers).
2. Water absorption is the ratio of the mass of water absorbed by a sample when it is completely immersed in water to the mass of dry matter. The ratio is expressed as a percentage. The water absorption of glazed ceramic floor tiles should not exceed 3%, while tiles with a water absorption of more than 10% can only be used on indoor walls. The water absorption rate of tiles plays an important role when tiling pools. To do this, you need to use only special tiles, such as porcelain stoneware or clinker.
   
   
3. Frost resistance - the ability of tiles to resist temperature changes. The durability of ceramic tiles is determined by two parameters: the presence and number of pores. Double-fired tiles are quite porous and therefore not frost-resistant. And single-fired tiles with a water absorption of less than 3% are considered frost-resistant. Porcelain tiles, unlike ceramic tiles, have a minimum level of water absorption - less than 0.05%.
4. Cracking is the appearance of fine cracks in the enamel coating. This happens with low-quality or incorrectly selected tiles under the influence of sudden temperature changes. This defect is sometimes present on the tiles before installation. When tiles crack some time after installation, the cause may be improper installation of the tiles: the use of poor mortar or glue, or a layer of these materials that is too thick or thin.
5. Slip resistance is a characteristic that determines the ability of a surface to prevent an object placed on it from sliding. This property is a basic requirement for the safety of residential and industrial premises, as well as for external floor coverings. In bathhouses, saunas and swimming pools, ribbed tiles with grooves are usually laid.
6. Chemical resistance is a characteristic of tile enamel, reflecting its ability to withstand contact with acids, salts, and household chemicals at room temperature. It must resist the aggressive or mechanical effects of these substances without undergoing external changes. Tiles can be protected by filling them with epoxy materials that are highly resistant to chemical attack.
7. Tone and caliber. Tone is the color saturation of the tile, which may slightly differ from the declared color. It is indicated on the packaging by a number or letter. Caliber is the actual size of the tile, which sometimes differs by a couple of millimeters from the nominal one. The caliber is indicated on the packaging next to the nominal size. During production, tiles are sorted into batches of the same size and tone with the tolerance for differences established by the standards.
   
   
8. Bending resistance. The higher it is, the lower the water absorption of the tile. Porcelain tiles have very high bending resistance, while porous tiles have lower ones.
9. Tensile strength - the level of possible load that the tile must withstand. It directly depends on its thickness. The ability to withstand loads is especially important for floor tiles. The tile covering should be able to withstand loads such as the weight of a person or furniture easily and not break.
10. Surface hardness is a characteristic that expresses the ability of a surface to be resistant to scratches and damage. Scratches are clearly visible on a shiny tile surface, but on a matte surface they are less noticeable.