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Introduction

Basic properties of building materials

Introduction

1. Product range

2. Technological part

2.1 Raw materials and semi-finished products

2.2 Choice of production method

2.3 Technological scheme for the production of ceramic tiles

2.4 Description of the technological scheme

2.5 Selection of the main technological and transport equipment

2.6 New in the technology of production of finishing materials and products

Conclusion

Bibliography

Introduction

Due to the huge volume of reconstruction of old and construction of new buildings, a wide variety of building materials and products is required.

The introduction of new technologies for the production of finishing works must begin with a serious and detailed study of them by bachelor students in the production of building materials, products and structures.

The particular relevance of these guidelines is caused by the training of specialists to perform an ever-increasing volume of repair and construction work and a significant number of objects carried out according to the principle of free spaces (without finishing the premises). According to an independent assessment, 60% of the country's housing stock is worn out by more than 40% and, therefore, modernization and major repairs are required. engineering systems with the subsequent furnish of premises at the modern level.

Finishing work is the final cycle of construction work, on the implementation of which an opinion is created and an assessment is given to the completed construction object.

Preparation of the base of surfaces for finishing remains an important and responsible stage of finishing work. To a greater extent, the durability and quality of the finish itself depends directly on the quality of the base and not even so much on the finishing materials themselves. Knowledge of modern work technologies and high qualification of performers also ensure the achievement high score finishing work quality.

The introduction of structures with decorative ready-made coatings, excluding finishing. These are designs of various types of suspended, hemmed, stretch ceilings, prefabricated office partitions and large-sized sheet materials with finished types of coatings.

Main execution task term paper- a reasonable choice of the method of production of a certain finishing material. The solution of this problem is preceded by the choice of the main material, raw material or semi-finished product, the development of a technological scheme of production, the choice of the main technological equipment.

The course work is an independent work of the student and must contain elements of new and original solutions to a given technological process in the production of finishing materials.

Topics of term papers are assigned in accordance with the practical tasks of the industry and must have industrial and scientific value.

The main topics of the course work are related to the development of modern methods for the production of finishing materials, with a variety of painting compositions, decorative plasters, wallpaper, ceramic tiles, facing panels etc., new technologies for mechanized application of dry mixes, a variety of each type of finish, etc.

For the production of finishing materials, there are many technological redistributions. Therefore, the possible topics of the work are not limited to instructions, but can be supplemented at the request of the student or the decision of the supervisor.

The presented materials can serve as a basis for studying and practical use new technologies and building materials, in an important issue - increasing comfort, environmental cleanliness and modern design residential and public buildings.

Coursework allows you to consolidate and deepen knowledge in the discipline "Finishing materials" and is a confirmation that the student is able to apply the knowledge gained in solving a specific problem.

Basic properties of building materials

Density a quantity equal to the ratio of the mass of a substance to the volume occupied by it is called; expressed in kilograms per cubic meter(kg / m 3).

True Density - the limit of the ratio of mass to volume of a body or substance, without taking into account the voids and pores in them.

Bulk density -- the ratio of the mass of granular materials, materials in the form of a powder to the entire volume they occupy, including the space between particles.

Average density - a physical quantity determined by the ratio of the mass of a body or substance to the entire volume occupied by them, including the voids and pores in them.

Relative density -- the ratio of the density of a body or substance to the density of a standard substance under certain physical conditions.

Porosity -- the ratio of the pore volume to the external volume (dimension) of the material. It is expressed as a percentage.

Porosity determines the basic properties of materials: strength, frost resistance, gas permeability, water permeability, etc.

Water absorption - the ability of the material to absorb and retain water. Water absorption is determined by the difference in the mass of a material sample in a water-saturated and absolutely dry state and is expressed as a percentage of the mass of dry material.

Water absorption by volume B is equal to the mass of water absorbed by the sample when it is saturated, divided by the volume of the sample.

The water absorption of the material by volume is less than 100%, and the water absorption by mass of very porous materials is more than 100%.

The ratio of the strength of a material saturated with water to its dry strength is called softening factor . Numerical value This ratio ranges from 0 to 1.

With a softening coefficient of more than 0.8, the building material is considered waterproof, with a coefficient of less than 0.7 - non-waterproof, and it is recommended to use it in wetted structures and structures with high humidity.

Moisture return - the ability of the material to give moisture when changing environment. Moisture yield is characterized by the rate of drying of the material per day at relative humidity ambient air 60% and temperature 20 °С.

Humidity material in percent is determined by the moisture content related to the mass of the material in a dry state.

Water permeability - the ability of the material to pass water under pressure. Water permeability is characterized by the amount of water that has passed through 1 cm 2 of the surface of the material in 1 hour at constant pressure. The degree of water permeability of the material depends on its density and structure.

Adhesion - the ability of a material to adhere to the surface of another body. Quantitatively, it is characterized by the specific work expended on the separation of bodies. Adhesion -- important property paint and varnish polymer coatings, anti-corrosion compounds, waterproofing and roofing emulsions and suspensions, etc.

Frost resistance -- the ability of a material in a state saturated with water to withstand repeated alternating freezing and thawing without visible signs of destruction and a decrease in strength.

Frost resistance is characterized by the number of sustained freezing cycles, determined by a decrease in the strength of the material by no more than 25% and a weight loss by no more than 5%.

The frost resistance of the material is checked by repeated freezing of samples at a temperature of -15...-20 °C and subsequent thawing in water at a temperature of 20...25 °C.

Thermal conductivity - the ability of a material to transfer heat through its thickness from one surface to the opposite due to the temperature difference.

Heat capacity - the property of a material to absorb heat when heated and give it away when cooled; characterized by a heat capacity coefficient equal to the amount of heat in joules required to heat 1 kg of material by 1 °C. The heat capacity per unit mass is called specific heat. The heat capacity of the material allows you to maintain the heat resistance of buildings.

Gas permeability - the ability of the material to pass gas or air through the thickness. The volume of gas passing through a layer of material is directly proportional to the wall area, gas flow time, pressure difference and inversely proportional to the wall thickness.

Sound transmission - the property of the material to transmit air and shock sounds. Enclosing structures of buildings are evaluated by soundproofing ability: a quantitative measure - decibel (dB). The soundproofing of the walls is characterized. an indicator of permeability from air sound, and interfloor ceilings - an indicator of sound insulation from air and shock sounds. For residential buildings, the sound insulation index from airborne sound of inter-apartment walls and interfloor ceilings must be at least 1 decibel, and the sound insulation index from impact noise of interfloor ceilings must be 0 (zero) decibel.

fire resistance - the property of the material to withstand prolonged exposure to high temperatures under load (without softening or deforming).

fire resistance - the property of a material to resist the action of fire during a fire for a certain time. It depends on the combustibility of the material, that is, on its ability to ignite and burn. According to the degree of combustibility, materials are divided into combustible, slow-burning and fireproof.

elasticity solid body called its property to spontaneously restore its original shape and size after the termination of the external force.

Plasticity a solid body is called its property to change shape or size under the action of external forces without collapsing; moreover, after the termination of the force, the body cannot spontaneously restore its size and shape, and some residual deformation remains in the body, called plastic deformation.

fragility of a solid body is called its ability to collapse without the formation of noticeable residual deformations.

strength a solid is the ability of a material to resist fracture under the action of stresses arising from a load or other factors.

The strength of the material is estimated by the tensile strength.

The tensile strength is the stress corresponding to the load that causes the destruction of the material sample:

where P razr is the load that causes the destruction of the sample,

F -- area,

M is the bending moment,

W is the moment of resistance.

Chemical resistance. The level of resistance of the material under the action of aggressive media - harmful gases, acids, alkalis and their solutions is called the chemical resistance of the material. The destruction of the material under the action of various reagents, moisture and gases is called corrosion. In industrial conditions, many building materials are operated under the influence of aggressive liquids and gases. IN Central Asia Basically, all buildings and structures are built on a saline base, which also acts aggressively on materials and leads to their destruction.

Most building materials are not resistant to acid, alkali and salt environments. Natural stone materials (limestone, granite, dolomite, etc.) are destroyed under the influence of acid. And materials from bituminous compositions, high-strength ceramic materials(plates, pipes, etc.), polymeric materials are resistant to aggressive media.

To determine the resistance of materials, a special chamber of aggressive media is used, and the samples are stored under these conditions for a certain time, then the results are compared with the reference ones.

Technological properties. The ability to change the state of the material in the process of their production is characterized by technological properties.

The technological properties of building materials include crushability, sawnability, grindability, nailability, etc.

Aesthetic properties. The sensory perception of architectural forms is associated with the aesthetic properties of building materials, which include color, shape, texture, texture, etc. These properties are important for the visual perception of the facade and the general appearance of the building.

Color - one of the properties of the objects of the material world, perceived as a conscious visual sensation. Each material has a certain color, which is perceived by sight.

White color consists of a complex of various colors. This essence was first revealed in 1666 by Isaac Newton using a special device. He noticed different spectra on a white screen, which are called Newton's spectra. There are 7 colors in the spectrum. They are arranged in the following sequence: red, orange, yellow, green, blue, indigo and violet.

The color of building materials is divided into achromatic and chromatic. Achromatic color consists of black, white and their mixture (gray). The remaining colors of the spectrum and their mixing with black and white are chromatic. A person can distinguish 300 achromatic and about 10,000 chromatic colors. Each chromatic color has 3 properties: hue, lightness and saturation.

Color tone characterized by the wavelength of radiation in nanometers: violet - 380-430, blue - 430-470, cyan - 470-510, green - 510-560, yellow - 560-590, orange - 590-620, red - 620-760. On the border areas are perceived mixed colors- yellow-orange, red-orange, etc.

Lightness - a dimensionless quantity used in lighting engineering that quantitatively characterizes the difference between the visual sensations caused by two adjacent monochrome surfaces. The lightness of a material can be understood as the relative brightness of its surface.

The degree of difference between a chromatic color and an achromatic color of the same lightness is called color saturation. Saturation characterizes the level, the strength of the expressiveness of a color tone; in the human mind, it is associated with the amount of pigment in paints.

Texture - the visible structure of the surface of the material. According to the nature of the surface of the material, two groups of textures are distinguished: embossed and smooth.

Texture - these are natural patterns on the surface of wood, natural stones, etc.

In finishing materials, texture and texture are determined by comparison with the standard.

Introduction

Ceramics (dr. Greek kEsbmpt - clay) - products from inorganic, non-metallic materials (for example, clay) and their mixtures with mineral additives, manufactured under the influence of high temperature with subsequent cooling.

In a narrow sense, the word ceramics refers to clay that has been fired. However modern usage of this term extends its meaning to include all inorganic non-metallic materials. Ceramic materials may have a transparent or partially transparent structure, may originate from glass. The earliest pottery was used as pottery made of clay or its mixtures with other materials. At present, ceramics is used as an industrial material (machine building, instrument making, aviation industry, etc.), as a building material, as an art material, as a material widely used in medicine and science. In the 20th century, new ceramic materials were created for use in the semiconductor industry and other fields.

Today, ceramic tiles have taken their rightful place not only in the design of bathrooms and kitchens, but can already be found in the design of any room. Modern manufacturers began to produce a huge variety of ceramic tiles of different shades of colors, shapes, textures and sizes, which gives unlimited possibilities in creating a unique style.

Builders got at their disposal the most diverse in size, shape, texture and color engobe, glazed, decorative mosaic tiles for facing walls and rolls, sanitary ware, new types of tiles, profile architectural inserts, three-dimensional sculptural art ceramics, etc.

Manufacturing methods:

1) Casting - the clay mass is poured into molds and fired. This is the oldest way to make tiles, but now it is not used: the edges of the tiles are uneven, and the tiles are not the same. This method is sometimes used in individual small factories, but such production is expensive.

2) Cutting - sawing natural stone (travertine or sandstone) into tiles. An even more expensive production method, which also has a low yield of tiles.

3) Extruding - stretching and cutting clay mass using a special machine.

4) Pressing - at the moment it is the most common and technologically advanced manufacturing method ceramic tiles. Finished products are as durable as possible, and also have high aesthetic qualities. There are two main pressing technologies ceramic coatings: bicottura and monocottura.

In modern ceramic technology, the following methods of decorating products of various purposes, shapes and sizes are used: a) glazing, b) engobing, c) coloring ceramic paints d) applying pre-made decorative images to the surface, e) staining with natural mineral dyes, f) two-layer molding, g) surface texturing.

Despite its venerable age, ceramics does not lose its attractiveness today. Facing with ceramic tiles continues to be one of the most convenient and practical ways to decorate rooms. Along with the decoration of the bathroom or kitchen that is familiar to us, the trend of using ceramic tiles in the interior of residential premises - bedrooms and living rooms, - decorating public buildings with ceramics and porcelain stoneware, is becoming more and more popular.

1. Product range

Ceramic tile is a flat, as a rule, thin-walled glazed or unglazed product made from ceramic mass, used for exterior or interior wall cladding and wall panels, as well as for flooring.

Ceramic cladding glazed tiles are designed for cladding internal surfaces walls and partitions of medical and commercial premises, canteens and kitchens, sanitary facilities, household premises, etc.

For the manufacture of facing tiles, white-burning clays and kaolin, quartz sand, feldspar, pegmatite, marble and some other components are used. The production of these products is carried out according to the method of semi-dry pressing of masses prepared by the slip method. the technological process consists of the following operations: preparation of raw materials, preparation and dehydration of slip, preparation of press powder, pressing tiles, their drying, glazing and firing.

All tiles can be divided into several groups:

ceramic granite (porcelain stoneware);

· terracotta;

two-burning tiles;

single-fired tiles.

Tiles are classified according to the nature of the surface - into flat, relief-ornamented, textured; according to the type of glaze - transparent or deaf, shiny or matte, one-color or decorated with multi-color patterns; in shape - into square, rectangular and shaped; by the nature of the edges - with straight and rounded from one or more adjacent parties(with blockage).

Currently, there are several main methods for the production of ceramic tiles:

pressing and then double firing (bicottura);

pressing and single firing (monocottura);

monoprose;

extrusion technology (cotto and clinker).

Pressing and then double firing (Bicottura) - enameled ceramic tiles are produced for indoor wall cladding. Enamel gives the ceramic tile shine and allows you to display the pattern of any design, and also protects the ceramic body of the tile from moisture penetration. The entire production cycle of this type of ceramic tiles takes place in two firing processes: the first to create the base, and the second to fix the enamel. The body of a ceramic tile (“cookie”) is obtained in this way: first, a moistened mass of red clay is pressed in special forms, then it is fired at a temperature of up to 1040 ° C.

Clinker tiles. Clinker tiles are sometimes simply called clinker, although real clinker is a facing brick, a very durable, non-absorbent refractory brick made of clay fired in a special way. Clinker belongs to the group of stone-ceramic materials, made from highly plastic clays. Since facade tiles perform the same functions as facing bricks - the exterior decoration of buildings, and are also often made in the form of bricks (to imitate brickwork), then such a mixture of names is permissible.

Another name is building clinker, clinker products. In general, clinker products are clay products fired to full sintering, usually in the form of a brick. The name "clinker" comes from the Dutch "klink", which means "clear ringing", since this is the sound that should be made when real clinker slabs are tapped against each other, which makes it possible to distinguish genuine ceramic tiles from tiles made of other materials. Clinker is also called a semi-finished product in the production of cement, which is a sintered mixture of limestone and clay (or slag).

Clinker belongs to the elite, high-quality finishing material. He received this recognition for high rates of strength and durability. Clinker tiles have low porosity, high mechanical strength and resistance to abrasion and chemical agents, which makes them particularly suitable for interior and exterior floors, stairs, exterior wall cladding of buildings (plinths and facades), as well as swimming pool cladding. Clinker tile is a fire-resistant material, therefore it is often used in the decoration of fireplaces, stoves. Also used for paving roads, cladding hydraulic structures, tank linings in chemical industries.

Clinker is made from heterogeneous types of clay with the addition of dye oxides, fluxes and chamotte. Clinker tiles can be pressed or extruded.

Classification:

In accordance with GOST 6141-91, tiles are distinguished by the following features.

According to the shape of the tiles are divided into square, rectangular and curly.

The side faces of the tiles can be without a blockage or with a blockage.

The value of the blockage radius is not a rejection sign.

Also, products of fine building ceramics can be faience, porcelain and semi-porcelain. They differ from each other in the degree of sintering of the shard, strength, and water absorption.

The front surface of tiles and fittings can be smooth or embossed, one-color or multi-color (decorated by various methods).

Decoration of tiles can be carried out by seriography, spraying, applying glazes with different surface tension, etc.

Glaze can be shiny or matte, transparent or muted.

Conventional designation of tiles in technical documentation when ordering, must consist of an indication of their type, color and designation of this standard.

Symbol example:

white square tiles without blockage, type 2:

Type 2 white GOST 6141-91

colored rectangular tiles with a blockage of four faces, type 33:

Type 33 colored GOST 6141-91

colored shaped corner pieces, type 38:

Type 38 colored GOST 6141-91

whites curly tiles, type 50:

Type 50 white GOST 6141-91

2. Technological part

2.1 Raw materials and semi-finished products

As raw materials for the production of ceramic tiles, mixtures of various materials are used, in particular:

1. clays and kaolin, which provide the plasticity of the wet mass necessary for molding tile blanks, ensuring sufficient strength of the semi-finished product in the dried state. But with an increase in their content in the mass, air and general shrinkage increases, therefore, the number of defects in production increases.

2. quartz sand, which forms the "skeleton" of the ceramic product, that is, it performs the structural function necessary to limit and control the dimensional changes of the product that are inevitable during drying and firing;

3. carbonate materials, depending on the nature of the action, are divided into fluxes (feldspars-aluminosilicates of sodium, potassium, calcium; pegmatite; dolomite, etc.) and lean (chamotte, quartz sand, etc.), due to which, during firing the desired viscosity is achieved, which provides a vitreous and dense structure of the finished product.

In addition to the main raw materials, additional materials are used in production, introduced into the mass as electrolytes - soluble glass, caustic soda, surfactants of organic origin (Sulfite-alcohol bard, etc.); bleaching materials - cobalt sulfate, etc.

Glaze is a mixture of various minerals and compounds (frits, kaolin, sand, various oxides, coloring pigments), which are applied to the surface of the product and melted. According to the sintering temperature, the glaze is divided into refractory (1100-1350 ° C) and fusible (900-1100 ° C). The fusibility of the glaze depends on its constituent materials.

Refractory glazes are applied to the product in its raw form, i. without prior melting. They include: quartz, kaolin, clay, natural carbonates of divalent metals (dolomite, marble, etc.)

Low-melting glazes are pre-fused. Materials for fusing these glazes: quartz, feldspar, borax or boric acid, strontium carbonate, magnesite, dolomite, etc.

Upon subsequent cooling, the molten mass solidifies, forming glass, which gives the top layer of the tile special properties.

During slip preparation of the mass, the clay components are dissolved in water to a colloidal state, thinning and fluxes are dispersed to particles less than 0.06 mm. The refining of the components, their mixing and homogenization of the slip mass occur in an aqueous suspension, which creates the necessary conditions for subsequent technological processes - molding, drying and firing.

Grinding and coarse grinding of clay is carried out in crushing and grinding machines for primary crushing (rollers of various designs, disintegrators, planers, runners); fine grinding and mixing of components - in ball mills. The duration of grinding of clay and lean is different, therefore, first, harder lean ones are loaded with a small amount of clay (up to 7%), which are crushed for 3-5 hours to prevent separation of the suspension. Then the rest of the clay is introduced and grinding is continued for another 2--3 h.

For more efficient grinding of the charge components, it is recommended to use strong surfactants that improve its rheological characteristics. These can be mono-, di- or trialkyl phosphate esters. They are added after supplying sufficient water during wet grinding.

Improving the technology of ceramic tiles in order to improve its quality is carried out at all stages of the process of its production - the selection and calculation of ceramic masses, the processing of raw materials, the preparation of slip and its dehydration during powder production, pressing, drying, firing and decorating products.

To improve the structure of the shard, it is recommended to additionally introduce porcelain production waste into the composition for producing ceramic tiles.

It is proposed to use chamotte dust as lean components, since the properties of ceramic tiles with the addition of chamotte dust correspond to the regulated indicators. High-quality facing tiles are also proposed to be obtained using waste from gravity coal enrichment. Here, a feature of the technology is the preliminary roasting of the rock to burn out carbon and activate the clay component. The cost of such a tile is 40% lower than usual. Facing glazed tiles in this case has the following characteristics: water absorption 12-17%, bending strength 12-14 MPa, average density 1.9 g/cm 3 .

For the manufacture of facing tiles, solid residues of mine water are also used; in this case, the tiles may contain iron oxide in the amount of 7-20%.

name of raw materials	Unit
Clay Veselovskaya
Sand quartz
Feldspar
Liquid glass
Fitta frosting
Pigments - dyes

2.2 Choice of production method

At the factories of building ceramics, products are produced mainly in three ways: semi-dry pressing from powders with a moisture content of 5–7% (main method), slip casting (clay suspension in water) with a moisture content of 30–33%, and plastic molding from masses with a moisture content of 14– -20%.

Products of building ceramics are generally obtained in the process technological processing clay raw materials with mineral additives, molding products, drying and firing (heat treatment) them to sintering of varying degrees, depending on the purpose of the product and the quality of clay raw materials.

Flow-conveyor lines (PKL) of ceramic tile production include a set of equipment, each unit of which is an independent unit in a single technology: semi-dry pressing presses, distributing and unloading devices for pressed semi-finished products before drying and firing, a slot dryer, glazing and decorating devices, high-speed firing kilns, installations for sorting and packing products.

The raw materials for ceramic tiles are the main components (clays, kaolins), thinning components to reduce shrinkage (quartz sands, natural and obtained by enriching kaolins), fluxes to lower the sintering temperature (natural - feldspars, nephelines, perlites and artificial - glass and slags) and additives (thinners, surfactants, mechanically activating, etc.).

Ceramic tiles for interior wall cladding are obtained mainly from red fusible, less often light refractory clays by semi-dry pressing of press powders with a moisture content of 6--7%, most often using slip

2.3 Technological scheme for the production of ceramic tiles

Figure 1 shows the algorithm for the production of tiles obtained by pressing in molds and further firing. In fact, each of the production stages for each type of tile has its own characteristics, which further determine the characteristics of the resulting material.

Figure 1. Algorithm for the production of tiles obtained by pressing in molds and further firing

Obtaining certain types of ceramic tiles primarily depends on the production technology. Figure 2 shows the main stages of various technological cycles and lists the main types of ceramic tiles that they allow to obtain.

Figure 2. Technological cycles for the production of various types of ceramic tiles

2.4 Description of the technological scheme

Raw material selection

Quartz sand, clay, feldspar and carbonate materials are used as raw materials for the base of the tile. The basis of ceramic glaze is frits - alloys of salts with glass. A glaze consisting only of frits has a glossy surface and is used in a double firing. To create matte glazes, quartz, metal oxides, kaolin, and coloring pigments can be added to frits.

Preparing the mixture

There are two technologies for preparing the mixture: wet and dry.

At wet technology raw ingredients are crushed and mixed in drum crushers in the presence of water. Crushers are huge drums rotating around an axis: grinding parts (stones or balls from a sintered mixture of aluminum oxide), hitting each other, crush the raw ingredients. As a result of grinding, an aqueous suspension of raw materials (slip) is obtained.

If it is necessary to press the mixture, the water is removed by the atomization process (countercurrent spraying of the slip with heated air with immediate evaporation of the water). As a result of this process, a mixture is obtained in the form of a powder, which contains 5-6% of the moisture necessary for high-quality pressing of the product.

If it is necessary to extrude the mixture, the residual moisture content of the mixture must be higher than the specified value: in this case, it is possible to remove water from the slip using a filter press.

With dry technology, raw ingredients are crushed in hammer mills and then moistened in special machines.

Grinding of the raw material is necessary to homogenize the mixture and extremely reduce its particle size, which facilitates the next firing process of the ceramic product.

Wet grinding technology is more expensive (requires a lot of energy to remove water) but gives much better results.

Single-fired, high-porosity and porcelain stoneware (gres) ceramic tiles are made from mixtures obtained by wet grinding, and ceramic tiles of the type are made from mixtures prepared by a dry method. Clinker tiles and double-fired tiles can be produced in both ways.

The preparation of the mixture consists of several operations that provide a homogeneous material, the desired grain size and the water content necessary for subsequent molding. At this stage of production, a powder with a water content of 4-7% for compression molding or a mass with a water content of 15-20% for extruded tiles is obtained. In any case, there are three main operations at this stage - grinding, mixing - homogenization, moisturizing.

When preparing the powder for pressing, two technologies can be used: dry grinding raw materials, followed by bringing the moisture level to desired values with moisturizers and wet technology when the raw material is crushed in water, followed by drying of the slip by spraying. The choice of this or that technology depends on the type of mass and on the characteristics of the product itself.

molding

All modern methods of molding ceramic tiles, according to ISO standards, are divided into three groups. Group A - extrusion method (production of cotto tiles, clinker). Group B - pressing method (porcelain stoneware, monocottura, bicottura). Group C included all other methods (hand molding, glass mosaic casting).

The pressing method is the most widely used. During pressing, the powdered mixture is loaded into the molds of a hydraulic press, where it is compacted under high pressure (up to 500 kg/cm²) and acquires a certain strength. At this stage, the tile may be subjected to additional processing. So, to obtain prepolished porcelain stoneware, the surface of the tile is polished with soft brushes even before firing. With the help of molds, not only the geometric shapes and sizes of ceramic tiles are set, but also the texture of its surface.

Pressing or extrusion are two molding methods used in the production of ceramic tiles. Pressed ceramic tiles are made from a powder mixture that is compacted and molded under high pressure using a hydraulic press through molds.

Extruded ceramic tiles are made from a dough-like mass of raw materials and are formed by passing through a special extruder hole using a die-die, which provides the ceramic tile with thickness and width. Next, the product is cut along the length with special knives (thin wire).

Most ceramic tiles are produced by pressing. During pressing, a powdery mass with a moisture content of 4-7% is compressed in two directions, usually under a pressure of about 200-400 kg/cm². Under pressure, the movement and partial deformation of the granules occurs, due to which even unfired tiles have the appropriate density and strength. Other types of products (fired products, clinker) are obtained mainly by extrusion, while the initial mass contains moisture from 15 to 20%, depending on the type of product. The strip exiting the extruder is then cut into appropriate dimensions.

Drying

During the drying process, moisture is removed from the product, which was necessary for molding. Its content is reduced to 0.2%. The process is carried out in dryers with hot air drying. Before entering the kiln, the ceramic tile passes through a drying chamber where hot air is supplied and where the ceramic tile loses the remaining moisture.

Drying plays an important role, since at this stage water is removed from the product, which is necessary for molding. Drying conditions are critical to product integrity, so the process is carefully controlled to avoid warping, cracking, or other defects. In the production of ceramic tiles today, the most common are dryers with hot air drying. Such an installation ensures the release of moisture to the surface of the product, its further evaporation and removal. The speed of the installation (the drying process lasts several tens of minutes) is ensured by good heat transfer, efficient ventilation and relatively high air temperature at which drying is performed.

Glaze application

To date, there are several dozen ways to apply glazes to the surface of ceramic tiles. Glaze can be applied in the form of granules, pasty mass or spray suspension. The moment of application can occur in different ways: before firing, after firing and even during firing. To give the tiles a more aesthetic appearance, the glazing process can be used in conjunction with the application of various images. One of the most common methods of applying ornaments is called silk-screen printing, when drawings are applied using paints through a special mesh with holes of different sizes and frequencies. The more complex the drawing, the more grids are applied.

Glaze is a mixture of various minerals and compounds that are applied to the surface of a ceramic tile and melted. Upon subsequent cooling, the molten mass solidifies, forming glass, which gives the top layer of the tile special properties. Glaze preparation consists in dosing various materials and grinding them in water. In this case, a suspension with a water content of 40-50% is obtained, ready for use. Glaze can be applied either to the fired surface (double firing) or to the dried surface as in single firing. Used to apply glaze different kinds equipment (cone or spunbond machines, bucket or tubular dispensers, disc sprayers, airbrushes). They are included in fully automated lines, which also include machines for applying ornaments (silk-screen printing machines). Some types of ornamentation may be applied after the glaze has been fired; in this case further heat treatment (third firing) is required.

Burning

Then the tiles are fired, which can last from 40 to 120 minutes. The kiln is a closed conveyor with a length of 50 to 80 meters. By supplying gas through pipes for every 20 cm of the furnace, a certain temperature is maintained at each point. Thus, in the process of moving through the furnace, the product is fired at a temperature of 200 to 1200°C.

The most important element of the tile firing process is the development and maintenance of a temperature curve. It is the correct construction of the temperature curve that is reflected in the most important technical indicators of the tile in the future. As soon as the batch of raw materials changes, the temperature curve must be developed anew. Therefore, it is very important for a tile manufacturer to have a permanent supplier of raw materials. And, therefore, only those manufacturers who have a long history of production are able to provide consistent quality. For each type of tile, an individual temperature regime is developed. different and Maximum temperature firing for different materials. For double-fired tiles - about 950°C, for single-fired tiles - up to 1180°C, for porcelain stoneware - up to 1300°C. In the process of firing at high temperatures, the tile loses moisture and decreases in size (shrinks). The shrinkage value increases with the firing temperature and can vary from 0% (for double-fired tiles) to 8% (for porcelain stoneware). Those. to obtain ceramic granite with a size of 300 * 300, the size of the mold should be 324 * 324.

Single firing(monocottura), when the glaze and base are fired together, is usually used to produce glazed floor tiles. The high firing temperature results in a well-sintered, durable biscuit, and provides the glaze with significant abrasion resistance. At this method production, it is impossible to obtain products of bright, saturated colors, since at high temperatures the coloring pigments burn out and fade. It has been observed that less bright glazed tiles are more resistant to surface abrasion.

Features of single firing, caliber

Monocottura, as well as its separate type Monoporosis, is an enameled ceramic tile designed both for wall cladding and for laying on the floor. It has a denser base made of white clay compared to bicottura, and therefore some of its types are frost-resistant.

The entire manufacturing process of monocottura takes place in one firing cycle. The prepared mixture, consisting of various light grades of clay with the addition of other natural ingredients, is moistened and mixed in special drums. Then it is dried in huge vertical silos and fed in the necessary portions onto a conveyor belt, followed by placement in a mold. There, with the help of a dispenser, there is a uniform distribution of the required amount of the mixture over the entire shape of the stamp. Modern presses used at the factory allow each tile to be pressed with a load of up to 500 kg/cm², evenly distributing the force over all surfaces.

At this stage, it is very important to note that the size of the tiles coming out from under the press is approximately 7-10% larger than the nominal size (this roughly corresponds to the moisture content in the batch after the press), that is, a tile that has a catalog size of 30x30 has yet Another size is approximately 32x32. Further, in the process of drying and final high-temperature firing, the tile, as it were, narrows, proportionally decreasing in linear dimensions. It must be understood that this is precisely what explains the presence of calibers assigned to tiles - in fact, the designation of its actual size. This is due to the fact that it is impossible to provide for this decrease in the firing process with an accuracy of a millimeter, it depends on many factors. Therefore, in the future, at the final stage, the tiles are sorted according to the actual size (caliber), which in turn has small tolerances, according to ISO standards. ceramic tile equipment raw materials

After leaving the press, the tiles are sent to a special final drying chamber, and then to the area where enamel is applied to the not yet fired tiles, which, after firing, protects the body of the tile and gives the appearance conceived by the designer.

After applying the enamel, the tile is fed into a furnace up to 100 m long. Gradually heating up there to a temperature of up to 1200 ° C, and then gradually cooling down, the tile goes through the same single firing, as a result of which the base acquires exceptional hardness and the enamel is fixed on it, forming a strong single whole. The whole firing process is strictly controlled by computers at each phase of the furnace. After leaving the furnace, the tile comes to the area for flaw detection and calibration, and then visual control of the tonality. Then it is sorted into batches, packed, labeled and delivered to the warehouse of finished products.

Tests at the flaw detection section consist in the fact that each tile falls on the so-called rails located along the edges of the tile and a roller is rolled in the center, acting on the tile with a certain load. If the tile has a defect, then it does not withstand the load and breaks, automatically not falling into further tests. Enamel surface defects are checked visually, at the same time as determining the tonality of the tile.

Properties of monocottura resulting from the technology of its production

The main differences between monocottura and bicottura are as follows:

? a thicker and more durable tile base, made exclusively from light clay;

? higher density as a result of using a more powerful press, and a higher firing temperature, and as a result, the presence of frost-resistant series (water absorption< 3%);

? stronger wear-resistant enamel, most often matte.

Scope, formats

Single firing tiles are produced in the formats 15.25x15.25, 16.5x16.5, 20x20 30.5x30.5 33.3x33.3 15.25x30.5 16.5x33.3. For most series, skirting boards and steps are produced in the appropriate sizes.

In many cases, monocottura tiles are offered as floor tiles for most bicottura series, thus complementing them. It can also be offered as separate series with wall decors and recommended for use on walls and floors.

There is also a special subtype of monocottura produced in 10x10 format. Tiles of this format are intended, as a rule, for facing the "apron" in the kitchen. They have a reduced thickness (approximately 6 mm) and a large number of different decors. Since this tile is mainly used in the interior, it does not have all the advantages of monocottura, but nevertheless it is stronger than bicottura and can be used as flooring in private interiors.

Monoporosis, raw material difference, properties and scope

A separate type of single-fired tile is monoporosis. This type of tile is produced by pressing and then simultaneously firing the body of the tile and the applied glaze. In this, it is completely similar to monocottura. But due to the use of several other components in the preparation of the batch, physical properties, and, accordingly, the scope of this tile, differ significantly, and are closer to bicottura tiles.

In the production of traditional high-density single-fired tiles (monocottura and porcelain stoneware), clays with a high content of iron oxide are used, and feldspar-based fluxes are used to speed up the sintering process and give strength. In the production of monoporosa, a fundamentally different clay is used - with a high content of carbonates. During firing, as a result of chemical processes, a rather porous white mass is formed, with high water absorption (up to 15%). The strength of such a tile is noticeably less than the strength of a conventional monocottura, so the base has a thickness of 12 mm. Naturally, such tiles can only be used indoors.

This technology makes it possible to bake slabs large formats almost ideal dimensions, which, after additional machining of the edges, can be laid with minimal seams. In the production of bicottura, where the base itself is made from red clays, the light enamel must be thick enough so as not to lose color. In monoporosis, the white base allows you to apply thin layer light enamel, realizing expensive graphic and chromatic effects. Decors are made both in the traditional way - by drawing a pattern on the tile, and by cutting with water under high pressure on special equipment: in this way you can get a very beautiful prefabricated decor, using, among other things, pieces of natural stone.

The white porous base and a thin layer of enamel require special rules for working with monoporous tiles: for laying it is necessary to use a white adhesive, it is necessary to rub the seams very carefully, trying not to damage the enamel. The surface for laying large format tiles must be perfectly flat.

bicottura

Double firing (bicottura) is used to produce glazed wall tiles.

The entire production cycle of this type of tiles takes place in two firing processes: the first - to create the base, and the second - to fix the enamel.

The body of the tile, the so-called base or "cookie", is obtained by pressing a moistened mass of red or white clay in special forms, followed by firing at a temperature of up to 1040 ° C. This tile is considered quite porous, with a water absorption rate of up to 10%. The thickness of the base, as a rule, is 5-7 mm, it is inferior in strength to all other types of tiles. The above properties determine its exclusively interior use for wall cladding.

The creation of "cookies" is a separate production cycle, after which the tiles undergo control of planimetry and dimensions. If the tiles do not meet the specified parameters, they are removed from the conveyor and sent for processing. To the second phase of firing - to fix the enamel, only pre-selected high-quality tiles are allowed.

The enamel covering the double-fired tiles is either glossy or matt. It does not have high surface strength as it is not expected that this tile used for wall cladding will be subjected to mechanical and abrasive loads.

The exception is some series that are recommended by the manufacturer and as floor. Naturally, they can only be laid on the floor in the bathrooms of private apartments and in no case in public places. At the same time, bicottura enamel is sufficiently resistant to household detergents used to clean ceramics, as well as to cosmetic and hygiene products that may come into contact with the tile surface in bathrooms.

Enamel application

Enamel painted in various colors applied in various ways. The main one, the so-called. roller - using the RottoColor machine - a large round drum coated with special material. The drum, rolling, applies liquid enamel, and since the length of its circumference is much greater than the length of the tile, 3-4 tiles are processed in one revolution, and the axial displacement of this drum is also often used. All this is necessary in order to make a larger number of tiles with a non-repeating pattern, while maintaining the selected design and color of this series.

Since the process of applying enamel does not affect the geometry of the tile in any way, these parameters are no longer controlled after the end of production, but are checked only for surface defects.

Bicottura properties and scope, formats

The main formats (in centimeters) currently accepted for production are: 20x20 20x25, 25x25, 25x33.3, 25x45, 12.5x45.

Bicottura is usually made in collections consisting of several colors that are combined with each other and with a large number of decors.

...

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Production technology ceramic tiles, which consists of such basic operations: extraction, transportation, storage of raw materials, preparation of ceramic mass, molding of products, drying and firing of raw materials. Semi-dry pressing method.

The method of manufacturing ceramic facing tiles depends on their type, material and equipment used. There are many videos and photos on this topic. But many are interested in knowing what is the difference between a tile and a production method and what is better to buy.

Let's say right away that it can be done with your own hands, but this will not be a cost-effective process. Requires significant production costs quality products.

In today's article, we will present the methods for manufacturing the most common ceramic tiles in our time.

The method of manufacturing facing is quite different. The production of facing ceramic tiles is a laborious and complex process that requires experience, professionalism and compliance important nuances and features.
After all, only then can you really make a high-quality and original product, which you need.

Attention: It is important to know that bicottura, monocottura and porcelain stoneware are considered to be the most common and popular materials in the modern world, which means that you must definitely take this into account.

In general, bicottura is a ceramic enameled tile, today it enjoys particular success, because it is increasingly customary to use it for wall cladding indoors. Thus, the room becomes elegant, luxurious and magnificent, and every owner dreams of this.

So:

• Enamel is able to give the tile not only shine, but also allow you to display a pattern of one style or another, and it does not matter whether it is a tile that is designed for the kitchen (see) or a tile for the bathroom.
• Speaking in general about the production of this type of tile, then know that it occurs mainly by firing, real professionals who know the subtleties and features of this work work.

Attention: It should be taken into account that the enamel with which it is customary to cover the tile can be either glossy or matte, which means that you yourself decide what exactly you need to purchase in order to enjoy the product.

• Enamel is famous for being able to show its resistance to household detergents, and more and more often they are applied to the surface of tiles in bathrooms (see).
• Such a tile can be easily recognized, because, as a rule, it has a slight thickness, weight, and a glossy shiny surface.

Attention: Few people know that bicottura today is mainly made in batches, they, in turn, may differ in colors. It all depends on the desire of the buyer, which means that you can purchase the products that you need.

It is also impossible not to add that the method of manufacturing facing ceramic tiles of this type can also be carried out using double firing - this is one of the most common and traditional methods for the production of ceramic tiles, if you remember the history, it has decades.

This is an enameled ceramic tile, which today enjoys no less success and popularity. It is customary to use it for wall cladding, for laying tiles on the floor, etc.

• By purchasing some types of such tiles, you will appreciate the frost resistance, which means that you can always use the products both outside and inside the premises, which is important.
• Speaking about the manufacturing cycle of this type of tile, then know that everything happens in one firing process. That mixture, which is carefully prepared, usually consists of different types of clay, naturally, other natural components must be added to it, after which all this is thoroughly mixed in specially provided containers.

How to distinguish bicottura from monocottura

Indeed, this question is of interest to many people, but in fact, it should be noted that there are some differences that make it possible to understand that these types of tiles really are seriously different from each other.

So:

• First of all, the great hardness of the material;
• Do not forget about the thicker and more durable tile base;
• You can also add hard, wear-resistant enamel here.

The enamel of tiles of this type is famous for the fact that it can really show high resistance to certain household detergents. You can also find on sale those tiles of this type that are distinguished by increased resistance to aggressive chemical environments.

Decors for monocottura

You should know that monocottura decors usually come in two types: floor and wall:

• Speaking about the production of floor decors, I would like to note that the process of their production is similar to the production of the base material, the only difference is that the blanks right size a drawing of one or another design is necessarily applied, in the future it is customary to burn it.
• You can purchase monocottura, which is presented as a floor product, it will have the color and size you are interested in. It can also be offered in independent batches. In any case, you need to understand that if you wish, you can always choose the type of tiles that interests you.
• During the production of traditional tiles, which are durable, it is customary to use clays with a high content of iron oxide, since this is the most important condition that must be taken into account without fail.
• This technology is known and widespread in that it is possible to fire slabs of various formats with ease and high quality, after which it is possible to stack products without significant gaps. Of course, every consumer dreams of this, so you will definitely appreciate it.

Attention: As soon as the production of bicottura begins, then know that it is imperative to use red clay as a base, and as for light enamel, in any case it should be thick enough, only in this way the product will not lose color, so you should remember this .

Gres. Ceramic granite

I would like to immediately note that ceramic granite in itself looks attractive, elegant and magnificent, which means that if you want to purchase such a product, you will immediately appreciate it as it should.

In general, this is a ceramic tile on which there is no enamel, it is not only beautiful and original, but also durable, moreover, you can find various shades and colors of such tiles on sale.

Advantages

The main advantage of such a product is low water absorption, which, of course, is important. Moreover, it is impossible not to add that the product is also distinguished by high resistance to chemicals, which is an equally important advantage.

• You will appreciate the depth of color, pattern, as well as impact strength, this includes high resistance to certain mechanical loads, and you must understand that these are really important advantages.
• Speaking in general about the main parameters for the production of this material, I would like to note that they are similar to the parameters that are customary to observe during the production of monocottura, but still, there are some significant differences, and you need to be aware of them.
• For example, the mixture from which it is customary to make porcelain stoneware usually consists of clays of two grades. As a result, such products are not only original and luxurious, but also, accordingly, durable, practical and reliable.
• You should also understand that it is porcelain stoneware (see) that refers to materials that are safe for human health, which means that by purchasing it, you will know for sure that it is.

Attention: Speaking about the range of production of such material, I would like to note that it is presented in a wide variety. This means that you can always purchase the version of ceramic granite that will satisfy your wishes and ideas, and this is the main thing.

Can be purchased different type surfaces, for example, matte or polished, it all depends solely on your taste and financial capabilities.

Matte coating

Such a surface indicates some features of the material:

• In the event that you decide to purchase a product with a matte surface, then be aware that it has a natural unprocessed look, it is obtained as a result of leaving the oven, and the product does not need further machining, be sure to remember this.
• The polished surface is beautiful, because the material sparkles, it acquires an unusual and interesting effect, thereby allowing you to get only a great mood from it.
• But you definitely need to know that such a tile turns out to be slippery if you pour water on it, which means that if you want to purchase such a product, then you need to take this into account in advance.
• Moreover, it is impossible not to add that it is difficult to care for such tiles, which means that you need to remember this, you need to clean it and you can only use special means, especially for the first time after installation.

Waxed surface

Such a tile looks luxurious and magnificent, worthy, it is worth seeing it once to be convinced of this. This is how it looks due to the fact that it is customary to apply transparent mineral crystals on its surface, which have different temperature melting.

As a result, the surface is shiny, moreover, it is also famous for being non-slippery, comparing, for example, with polished tiles, which, of course, is its main advantage.

Smalted ceramic granite

Speaking about the manufacturing technology of this material, then know that it is similar to the technology and production of monocottura. The enamel that is applied to the surface of the product and will determine the color and texture of the surface.

• But one cannot but add that retified tiles are also very popular today, if you start using them, you can create a single, original and attractive surface that will differ in that seams will not be visible on it, which pleases.
• As a result, you can enjoy the fact that a surface has been created that is lined with natural stone, of course, you will definitely appreciate it, because the surface will look unusual and interesting, and this is the main thing.

Retification is an additional mechanical restoration, usually, we are talking O finished material. Here the tile is cut off the side edges, this work is carried out on special machines so that you can give the products originality and elegance.

• Moreover, it is impossible not to take into account the fact that the equipment is carefully configured, as a result, it is possible to process different formats in one batch, while respecting the given pattern.
• Naturally, you need to understand that real professionals who know their business work behind such machines, this is the only way to get high-quality and durable products that will serve as a real decoration for a long time.
• It is important to say that it is thanks to the presence of such equipment that it is possible to lay tiles of various sizes, which, of course, cannot but rejoice. Moreover, it is always possible to produce a clear combination of matt and polished tiles of the same series.

As a result, you can get a surface that will not only look decent, but it will not have any seams, which, of course, can positively affect your mood, and this is the main thing.

In general, the production of any of the listed types of tiles is notable for its complexities and important features that must be observed without fail. After all, only then it will be possible to achieve results, obtaining high-quality and reliable products, which are also original.

Conclusion

The production of facing ceramic tiles today is actively developing, moreover, each consumer will be able to purchase, without any problems and difficulties, those products that he dreams of, which, of course, cannot but rejoice.

But it is unlikely that it will be possible to produce it on its own, I mean in series. It's easier to buy. After all, the cost of production is quite high.

• After all, you are well aware that the production of such products is really developing at the moment. If you want, for example, to purchase ceramic granite, then you can do this without any problems, remember that you can choose the surface that will decorate your home as it should.
• You can buy a product with the texture of "old stone", of course, it will look unusual, decorating any home, so you should think about buying just such products.
• Today you can buy a tile that is designed specifically for pools, it looks completely unusual and interesting, which means you can always enjoy it as it should.
• In addition to the attractive appearance of such products, they are also distinguished by durability, practicality and reliability, which means that it is worth giving preference to them, evaluating products properly.
• Many consumers choose matte surfaces for products of this type, as they look unusual, interesting and luxurious.

Attention: If you want to buy floor tiles, then you will be offered a wide variety of sizes and colors of such products, which will allow you to get what you need.

• You can always produce a clear combination of such products, thereby making the room look unusual, cozy and comfortable, naturally your family and guests will definitely appreciate it as it should.
• On sale you can find a special subtype of monocottura, which, in turn, is produced in a 10x10 format. If you decide to purchase tiles of this format, then be aware that designers advise you to do this. Only when buying, the instructions should be studied, because you need to know its parameters.
• After all, the products are unusual appearance, so if you want to beautifully veneer the “apron” in the kitchen, then you can purchase just such products, thereby getting a great mood from this.
• Summing up, I would like to add that today tiles are made in a very diverse way, but the good news is that you can find various types of it on sale, which means that if you wish, you can purchase a product that will differ not only in attractiveness, but also in durability, practicality, and it is most important.

Therefore, as soon as you decide to purchase such products, you need to carefully analyze everything, choosing really the tile option that is ideal and optimal for a particular room. Everything is in your hands, we hope that our advice and recommendations will allow you to make the right choice of tiles that you have been dreaming about for so long.

-> Production, construction, Agriculture

Production of ceramic tiles.

Tile, as one of the most popular building materials, has always been in demand. People do not stop building, renovating apartments even during a crisis. And if large manufacturers specializing in the manufacture of tiles for new buildings, today during the crisis "specifically suffer" in the first place, then focusing on the provision of tiles individual apartments, You will always remain in the "plus".

Advantages and features of the production of tiles

IN this case, small business, in contrast to large production, has several quite "solid" advantages. Firstly, this is a wide variety of finished products, which a large manufacturer can hardly boast of. The depreciation also played into the hands of “small” tile manufacturers national currency, significantly increasing the cost of imported products.

The main competitive advantage of small production tiles- the possibility of producing really high-quality products at prices below competitive prices.

Equipment for the production of tiles

For the purchase of a minimum set of equipment necessary to start production ceramic tiles it will take about $10,000.
For this amount you will receive: a concrete mixer, a vibrating machine, molds for tiles, a chamber for spraying patterns, glazes and a semi-industrial oven for drying products at a temperature of about 200 degrees. Equipment for the production of tiles can be purchased as a set or separately, which will turn out a little cheaper.

However, in order to produce not a standard tile, but something exclusive, unique, it is necessary to acquire additional devices. A multifunctional modernized sputtering chamber will cost from $3,000. To apply various patterns, you will also need a set of stencils. Approximate cost of a set of 200 pcs. stencils - about $ 600.

It is also possible to purchase a mass of other very diverse devices that make it possible to make a tile, for example, self-luminous, however, standard set will be enough to produce wall, and floor tiles.

Materials, premises and personnel for the production of ceramic tiles

The quality of the finished tile largely depends on the quality of the materials used for its manufacture. It is better to use high quality cement and granite screenings. Also, you will need plasticizers, dyes and glaze. Based on monthly production tiles to cover 5,000 square meters, the cost of raw materials will be about $12,000.

To organize the production of a given amount of tiles, 4 workers will be enough: 2 workers near the concrete mixer, 1 for servicing the vibrating table, and another one will be engaged in drying and packing tiles. In addition, to ensure the proper quality of products, it is necessary to hire a master with knowledge of the technological process.

Requirements for a business premises production of ceramic tiles minimal. The required area is about 100 sq.m. It can be a cold warehouse, a barn - almost anything that has walls and a roof ...

Payback for the production of ceramic tiles

• $10 thousand - equipment for the production of tiles,
• $12 thousand - raw materials,
• about $3 thousand - salary workers' wages,
• about $ 1 thousand - rent of premises and payment for electricity (may differ significantly).
• $1.5 thousand - for the organization of production and opening a business.

As a result, one-time costs will amount to $30,000, and about $18,000 monthly.

We will calculate income based on the average cost of selling a tile at $ 7 per square meter. With a production volume of 5 thousand sq.m. the total monthly income will be about $35,000.

However, if you think that everything is so perfect and smooth, as you can see from preliminary calculations, you will have to be a little disappointed.

Seasonality and markets.

Ceramic tile- products that are very dependent on the season and fashion trends. Demand for tiles in winter is almost zero. It makes no sense to work for the future in the cold season, since the tiles produced by the next year may no longer be in fashion. Demand for ceramic tiles is activated in the spring. In the summer, you should not have problems with the implementation.

Relatively sales market- everything here is according to the standard: through repair teams, advertising and exhibition stands at construction markets and fairs, the Internet and other methods to express yourself and attract customers.

Thus, real term The return on investment will be just over 1 year.

And remember, without ceramic tiles today not a single major repair is done. There are many ceramic tile shops in Russia, their range will enrich your imagination in terms of tile design and will be a reliable guide to modern renovation trends.

For the manufacture of tiles in a factory, the following equipment is required:

• Concrete mixer: Designed for mixing cement and other ingredients.
• vibrating machine: Designed for compacting concrete mix.
• Forms: designed to form tiles.
• special chamber: designed for spraying pattern and glaze.
• Bake: designed for drying formed products.

The listed equipment will be enough for the manufacture of ordinary or standard tiles. But, if the manufacturer decides to produce more unique products, then he will need some other devices. It could be:

• Multifunction camera for spraying, which costs a lot of money.
• Set of professional stencils, with which the drawings will be applied.

The price of equipment for the production (manufacturing) of ceramic tiles is rather big. But the payback is good.

The video below discusses special equipment for the production of tiles:

Calculation of raw materials

For the manufacture of tiles you will need the following materials, each of which performs a specific role in the raw material:

• (responsible for maintaining the size after the drying procedure).
• (responsible for the elasticity of the mixture).
• Feldspar composition (responsible for viscosity).
• Carbonate composition (responsible for viscosity).
• Various supplements.

For the production of tiles, refractory or refractory clay is needed. The latter option is most suitable in terms of the amount of impurities.

To bring the clay to the desired state, various additives are used. They are of the following types:

• Glaze (creates a protective layer and gives the product a beautiful aesthetic appearance).
• Thinning additives (they reduce clay shrinkage and make plasticity several times less).
• Plavni (reduce the melting point of clay).
• Plasticizing (make clay more plastic).
• Engobe (used for decorative processing of the product).
• Vaporizing (make the structure of the product more porous).

Manufacturing technologies

The production of tiles differs little from the manufacture of ceramic products. It has remained unchanged over the years.

factory methods

Tiles in factories go through the following stages:

1. Mixture preparation.
2. Formation of products.
3. Drying in chambers.
4. Glazing tiles.
5. Roasting in a kiln.
6. Product sorting.

Preparation of the mixture and the formation of products

At the preparation stage, the components are mixed to obtain the necessary uniformity. First of all, the clay is crushed, then various additives are added to it to obtain the desired chemical.

Before the formation stage, the clay must be moistened. How much the raw material will be wetted, and what additives will be included in it, depends on the performance of the finished product.

Molding refers to the pressing of products. To do this, the prepared raw material is poured into molds and pressed under a pressure of 400 kg/cm 2 . As a result of this process, a fairly strong and very dense product is obtained.

Drying and glazing tiles

During the drying phase, unwanted moisture is removed from the products. This stage has special meaning. The fact is that moisture will evaporate during the firing process. The resulting steam greatly destroys the integrity of the tiled products.

If the drying step is neglected, then a lot of rejected products can be obtained at the output.

Glazing is necessary to give or light shade. Glazing is applied before the firing step. High temperature and subsequent cooling turn such a coating into a specific glass.

Such a coating performs protective functions. As a result, the tile not only gets an aesthetic appearance, but also protects the product from negative influences.

Roasting and sorting of products

Another very serious stage is roasting. The high temperatures of the oven lead to the necessary chemical reactions that cause physical changes in the tiles. In the furnace, the products move along the tunnel.

The oven temperature is different. It ranges from 900 to 1300 ºС. It is very important at this stage to gradually decrease the ambient temperature. With a non-smooth transition or with a sharp change, the product may be deformed.

At the stage of sorting, the products are subjected to verification. Here we estimate the thickness dimensions, the presence of cracks and the degree of marriage. Only after that the tile is packed and sent for sale.

IN next video the production of tiles in the factory is presented:

DIY

For self-production of tiles, you will need to go through the following steps:

1. Raw material preparation.
2. Raw production.
3. Biscuit firing.
4. Subsequent decoration.

Raw mass preparation and raw material production

At the first preparatory stage, it is very important to choose the right type of clay. Here it is necessary to take into account its plasticity. Plastic raw materials allow you to form absolutely any shape.

The best option in this case is clay of medium fat content. If there is clay with a high fat content, then the value can be averaged, sand, pumice or fireclay can be added to the material. This method will avoid rupture during firing and make the raw material less refractory.

After mixing the components, the resulting mass is wrapped in a plastic bag. It is very important to completely block the access of oxygen. The raw material must absorb the available moisture. Air pockets in the tiles greatly reduce the quality characteristics. This method will significantly improve the quality of the clay.

For molding use polyurethane molds or any other suitable characteristics. When shaping, it is very important to distribute the clay well in the form and carefully compact it. In this case, the thickness of the future product over the entire area of ​​\u200b\u200bthe mold should be the same.

The prepared cheese is dried. Readiness is judged by hardening and lightening of the tile.

It is important to remember that the raw material itself is very fragile.

Firing and subsequent decoration

Roasting is also carried out at high temperatures. The result should be a glass-like product. At home, it will not be possible to achieve a temperature of 1300 ºС, 850 ºС will be enough. Biscuit firing is called because the raw material shrinks. This must be taken into account when calculating the dimensions of the product.

At the stage of decoration, you can show imagination. Various drawings will decorate any product. The most important thing here is to use the glaze. It can be applied with a brush or simply by spraying. Often used and the method of pouring. Glossy shine is achieved with varnish or enamel.

At the end of the decoration, the product is fired a second time. It is important here not to exceed the set temperature value, otherwise the tile may crack.

The video below shows the process of manual production of ceramic tiles:

Production of ceramic tiles as a business

The tile business will always be there. By opening your own mini-production, you can quite easily find buyers due to the fact that tiles will cost a little cheaper than competitive manufacturers. However, it will not differ poor quality. It is these two factors that always come first for the consumer.

So, the purchase of equipment will require approximately 300,000 rubles. The purchase of material will require about 350,000 rubles.

You will also have to pay for additional equipment:

• Multifunctional spray chamber: approximately 90,000 rubles.
• A set of professional stencils: 18,000 rubles for 200 pieces.

In addition, it will be necessary to rent an area where the equipment will be installed and the production process will be carried out. On average, this will take about 35,000 rubles. This figure also includes the considerable cost of electricity.

The process is not automated, so you can’t do without workers here. On wages service personnel will allocate about 90,000 rubles. At the same time, money will be required for the process of opening a business. This is approximately 45,000 rubles.

We divide these costs into two types:

• Disposable, which will amount to 453,000 rubles.
• Monthly, which will be approximately 475,000 rubles.

To determine income, we will assume that the production volume is 5,000 m 2 tiles. Let the price per square be 210 rubles. Then the monthly profit will be equal to 1,050,000 rubles. Net income minus monthly expenses will be 575,000 rubles. It will take a little more than a year to fully pay off the invested costs.

The amount of income from the production of tiles is very good, but all those are so smooth. This business has its pitfalls.

• Firstly, the sale of tiles is very dependent on the season. So, very few people buy it in winter, mainly people start thinking about construction and repair in spring and summer. It is at this time of the year that you can count on the full sale of the tiles made.
• The second factor is fashion trends. It is impossible to produce a tile in full in months when it is in little demand. After all, time will pass and the tile will become unfashionable and not interesting. The demand of buyers for it will fall.

Despite the fact that the production of ceramic tiles is carried out by hundreds of enterprises around the world, its organization is considered a promising, successful investment.

Production line for the production of ceramic tiles

These statements are based on the following factors:

• The construction industry consumes more and more materials, among which ceramic products occupy a prominent place, the demand for them is growing.
• The production of ceramic tiles is a well-established technological operation, it does not require large allocations for research work. The methodology for the production of works is described in detail and tested by many years of practice.
• Basic raw material- clay is cheap and widespread, often its extraction is carried out near the production, the delivery shoulder is small, which reduces the cost.
• The variety of equipment for the production of various capacities and prices allows you to choose volumes and a specific line of business.

In the near future, an alternative to ceramics is unlikely to be found. An enterprise producing ceramic tiles need not worry about the prospects, its products will be in constant, steady demand in the building materials market.

In addition to automation, people also work at the enterprise. So the OCT of the tiles that you see in the picture is partially performed by a person

Considering a product such as ceramic tiles, the production technology of which is given below.

It must be remembered that the algorithm of work of all enterprises producing building products is approximately the same:

• Sorting and storage of raw materials
• Mixing the ingredients into the primary mass
• molding
• Mechanical, thermal and other physical effects on the source material
• Quality control and warehousing.

Ceramic tile production technology is a series of activities that consistently lead to the creation of a finished product.

On open areas you can only see the sliding tiles from molding to packaging

One of the secrets of getting a quality tile is careful pre-selection and proportions in mixing the main components: clay, sand, feldspar. All components must be pure, without impurities. Quarry clay is not suitable for production, it must first be prepared for further use. Raw materials for the production of ceramic tiles are crushed in crushing and grinding machines, iron oxides are removed by magnetic separation.

In these kilns, tiles get their hardness

Industry leaders know that the quality production of ceramic tiles largely depends on chemical composition clay. Raw materials taken from different deposits require correction of temperature regimes each time, which often leads to a change in the tone of the tiles of the same series. Therefore, they prefer to deal with regular suppliers who bring raw materials from proven quarries.

Crushing and mixing pursue the main goal - the creation of the most homogeneous mass. Depending on the molding method, water may be added to it.

In this photo you can see the tile being dried. In a couple of minutes, all the shelves will be filled and the robot will transport the tiles.

The formation of the geometric dimensions of future products occurs in one of three ways:

• extruder. The mechanism pulls the pasty mass into a wide tape of a specified thickness, here it is cut into fragments.
• press. A hydraulic device with a special stamp squeezes the prepared mixture from both sides with a force equal to 300–500 kg / cm 2.
• casting. Diluted to a semi-liquid state, the mass is poured into pre-prepared forms.

It should be noted that the first two methods are more widespread.

If, immediately after molding, a raw tile is fired, then the excess water break the material. In order to prepare the semi-finished product for further operations, it is subjected to pre-drying. After its implementation, the moisture content in the clay should be 0.1–0.3%. The time allotted for drying in high-speed dryers depends on the density and thickness of the workpieces. Thus, the production of ceramic floor tiles involves drying the semi-finished product for 30–60 minutes.

And this is how the transportation of tiles for final packaging by a robot looks like

The main heat treatment of the material is carried out in special furnaces. The manufacturing technology of ceramic tiles provides for two options for firing. Ceramic granite, the bulk of the floor and wall decorative tiles are made using the single firing technique. According to this technique, glaze is first applied to the semi-finished product, and then it is sent to the oven, where the mineral components are sintered at a temperature of 900–1400 0 C, and a monolithic strong structure is obtained. The production of double-fired tiles involves first firing a clay shard, then applying glaze to it, and then firing it again at a lower temperature, sufficient to melt the glaze, but not affecting the structure of the base.

The brand of the production line manufacturer flaunts in the most prominent place.

In some cases, the technology for the production of double-fired ceramic tiles includes the process of engobing, that is, applying a thin layer of a mixture of high-quality clay, cullet and minerals to the surface after the first firing. This underglaze improves the surface quality after the second firing.

If the tile on the line is moving, then the process of its preparation has not yet been completed.

The production of floor ceramic tiles has its own characteristics. They consist in creating additional conditions conducive to the complete sintering of the mass. For this purpose, fluxes (pegmatites, sodium and calcium spars) are added to the charge. The result is improved flexural strength and improved abrasion resistance. In order to speed up the firing process, additives (talc, magnesite and dolomite) are used. finished tile undergoes quality control and sorting by series.

Stop happens only in three cases: drying, preparation for packaging, line breakage

Technological scheme for the production of ceramic tiles

Here is a visual diagram of the production of various types of ceramic tiles

The production of ceramic tiles presented in the video clearly illustrates the whole process.

Equipment

Equipment for the production of ceramic tiles is widely represented on the market, it is constantly being improved. The choice is great, you can purchase individual units for small factories or powerful high-performance mechanisms for mass production, it all depends on the intended purpose.

This machine makes a pattern on a tile
Here's what's going on inside. This is how the drawing is applied. Very similar to printing. True, the ink of such a printer is special

An indicative list is compiled taking into account the tasks performed by the equipment:

• Preparation and mixing of components into the primary mass. Ball mills, various crushers, distribution tower dryers, special mixers. Concrete mixers are often mentioned on the Internet. If a small handicraft production - why not;
• Molding. Presses, extruders, molds;
• Pre-drying. Single-row high-speed dryers on mesh or roller conveyors.
• Glazing. Airbrushes, spunbond and cone machines, disk sprayers, screen printing machines, tubular and bucket dispensers;
• Burning. Gas or electric tunnel ovens with conveyor and program temperature control.

If individual mechanisms are installed in accordance with technological requirements, united by automatic transport and common system management, then a ceramic tile production line is formed.

This is a mill. The most genuine, only for the production of raw materials tiles

This is the optimal production configuration. Achievements in the field of informatics make it possible to computerize the entire process, to reduce human participation to a minimum. Leading ceramic manufacturers use just such lines. For example, ceramic tiles produced in various developed countries are almost entirely made on such equipment.

Tile decoration

The manufacturing technology of ceramic tiles has experienced a rebirth in recent years due to the emergence of new methods for applying patterns or paint layers to its surface. Moreover, it is important that these are not water-washable decals, but component the product structure itself.

TO traditional methods staining - pigmentation of the mixture, the introduction of mineral additives into the glaze, a new method was added - photo printing. Technology of printing on ceramic tiles includes methods: sublimation; the use of inks that interact with ceramics under ultraviolet irradiation; method of "hot decal"; transferring special ink to tiles by printers.

On such lines, tiles are polished and prepolished

Today, the production of ceramic tiles is largely focused on individual orders. The above methods help to embody any artistic intent of the client in ceramics.

Can you make ceramic tiles yourself? Of course. The production of ceramic tiles is based on thousands of years of practice. People were making ceramics long before hydraulic presses and other modern mechanisms. The simplest mechanisms to help prepare and mix the mass, apply glaze and fire are quite affordable. In order for the do-it-yourself ceramic tile, the manufacture of which is planned, to turn out tolerable, it is necessary to take care, first of all, of the quality of the clay. Since, in manual production, the use of a press is not provided, everything depends on the fine-grained homogeneous structure of the prepared mass. The procedure for glazing and firing can be found by sending the request "ceramic tile production video". Just be aware that ceramic tile making equipment will require a lot of space, mixing machines are noisy, and ovens are fire hazards. Safety precautions must be strictly observed.

In these furnaces, the melting temperature reaches 1200 degrees Celsius.

If the technique is well studied and all technical requirements, then it is quite possible to establish your own small production. A photo of self-made ceramic tiles demonstrates that perseverance and the right approach business is bound to lead to success.