As the rest of the world descended upon the Motor City this past February for Superbowl XL, I boarded a transatlantic flight to Valencia, Spain for the 24th annual CEVISAMA (www.cevisama.feriavalencia.com) ceramic tile expo; traveling as a guest of Tile of Spain and ASCER, the Ceramic Tile Manufacturer’s Association of Spain. Held February 7 – 11, 2006, at the newly renovated Feria Valencia center, CEVISAMA is the international trade show for ceramic tiles, surface coverings, bathroom and kitchen equipment, raw materials, glazes, frits and machinery (displayed only even years), and this year’s installment featured over 1,400 exhibitors in addition to setting an attendance record for the show.

CEVISAMA 2006 was held in the recentlyly-renovated Feria Valencia center (pictured), and featured over 1,400 exhibitors. Photo by Joseph H. Mayton III

Myself and other members of the U.S. press were traveling in a group, and toured by bus to the show each morning. Patti Fasan, CTC, and Rocamador Rubio, Tile of Spain, played dual roles of tour guides and teachers, leading us around the show to different booths and displays.

Over the years, increasing awareness of tile’s natural and long-lasting lifecycle has made its use more prevalent by architects, builders and consumers.

With a rich, historical use in buildings throughout the world, modern ceramic/tile products serve both a design and technical function, providing unlimited design possibilities, and meeting contemporary performance standards.

With product lifespan an important factor to consider when choosing a flooring material, ceramic tile’s longevity is reported at up to four times that of other materials. For example, carpet may need to be replaced within five to 10 years, where tile will last indefinitely longer.

“There can be nothing more environmentally friendly than architecture that is built for centuries rather than decades,” said Patti Fasan, CTC. “Selecting quality products that are durable and will not need to be replaced within the life of the structure substantially reduces resource extraction, manufacturing, transportation, installation and demolition energy requirements. When materials also offer: reduced maintenance; improved indoor air quality; low toxicological impact; and are inert, low burdening waste at the end of their life, we should be considering these products along with materials being promoted solely due to their recycled content,” Fasan said.

Chamota (top) is part of the ingredients included to make the clay mixture, which is then forced through an extruder as a smooth, continuous ribbon (bottom). Photos by Joseph H. Mayton III.

The ceramic tiles of Spain are made from natural clay and raw materials, with a manufacturing process that utilizes regional materials and places regulations on water usage, making recycling an element of production. The tile can be categorized by its surface, the firing process and the shaping used in its manufacture.

There are various types of ceramic tile, the most common for floors being stoneware floor tile, which is made of vitrified clay and is usually glazed.

Porcelain tile is a dense, pressed tile with an impervious body, and are available glazed or unglazed for both interior and exterior use.

The group visited numerous booths, including Rosa Gres, Roca, Tau Ceramica, Mensaque Rodriguez, Natucer, Adex, Decorativa, Onix, and Colorker, whose Tecktonia four-nozzle system — which operates similarly to a color computer printer — employs a “nano-particle” digital printing that sprays colored clay nano-particles onto the tile’s surface and uses natural colors and no inks or glazes to coat the tile, and was treated to demonstrations and presentations on tile product and their attributes.

The myriad styles, looks and applications of the various displays showcased tiles that resembled a number of different materials: wood, metal, glass — each unique and visually appealing in its own way.

production process

In addition to touring the CEVISMA show floor, Tile of Spain also arranged visits to two local tile production facilities, Natucer and ADEX.

Natucer, who produce extruded tile that is glazed while still wet, has a production facility in Onda, near Castelleon — about a 45 minute bus ride from the city of Valencia. Upon arrival, we visited the showroom in the upstairs office, and then headed out behind the warehouse to where the clay materials are stored.

The tour guides explained that due to the levels in the local clay being less than ideal, the clay used to make the chamota — a clay mixture — is brought in from a location approximately 80 miles from the production site, and is chosen for its greater plasticity.

The tile manufacturing process begins with materials from the reserve being ground and mixed to form soft clay, which is forced through an extruder as a smooth, continuous ribbon — there are lines along the backside of the tile as a result of this procedure.

The clay is formed to desired shape, and then cut into individual tiles of assorted sizes.

Waste of materials is virtually eliminated in the manufacturing process by recycling 100 percent of scraps from the tiles as they are cut, and sending them back to the beginning of the process to be reground and reformed into fresh material.

Historically, series of tiles have reflected cultural, architectural and artistic themes, and the diversity in terms of size, shape and color further etablish tile as a superior design tool in both aesthetics and functionality. Photos by Joseph H. Mayton III.

“The manufacturing process recycles 100 percent of retained production water, resulting in a drastic reduction in water consumption. In the past twenty years, the industry has tripled its production yet managed to reduce gaseous emissions by 75 percent of original 1970’s consumption levels required to produce one third of the product,” Fasan said.

Following this shaping process, the tile is placed onto a belt that carries it into a 1200 degree oven, where it is dried and removed for packaging.

The next morning we visited and toured the ADEX facility in Valencia, where we again walked the production line as tiles went through processing from start to finish. The clay is produced at a separate facility, and arrives at this location in blocks that are then hand cut and thrown into the grinder. This process was different from the previous tour, and the tiles were formed and dry before being immersed in the glaze, which was a station function on the conveyor belt ride.

After being coated, the tiles were picked up on a sheet by a robotic arm and physically turned to remove any excess glaze from the sides of the tile so they will adhere properly when laid. The tiles are then fired, and after that the edges of the dried tiles are sanded manually at a belt-sanding station to round off for molding, etc.

lifecycle attributes

With the technological advancements, it is possible to make tiles that are color-specific, long-lasting and are easily repaired; instead of replacing entire installations, it is possible to replace individual tiles, etc.

“Ceramic tile is the hero of disasters, and can be repaired if damaged by water, fire or mechanical impact without replacing or disposing of the entire flooring material,” Fasan said. “Setting aside a reasonable quantity of reserve stock, from the original production lot, can also double the life of the floor or wall as it enables replacement of any naturally worn or trafficked areas. This feature greatly reduces the need for replacement material and resources.”

Maintenance is simple, and can be kept up with non-toxic materials and solutions.

Ceramic tile is not an original nor secondary source of air pollution, and will not absorb odors from smoke, paint fumes or other contaminants, lending to enhanced indoor air quality (IAQ). According to Fasan, the exceptional durability of ceramic tile is directly related to the impervious glazed surface, which, requires low-cost maintenance and no chemical or protective finishes. “Warm water and neutral cleaners are the only cleaning products required,” she said. “This easy maintenance contributes to consumer cost savings over the life of the installation. Additionally, ceramic tile does not contribute to the level of toxic cleaning products being flushed into our ecosystem by materials that recommend the use of chemicals, soaps, shampoos, waxes, strippers, and solvents.”

With a long lifecycle as well as natural durability and low-maintenance attributes inherent to the material, it is easy to see why ceramic tile should be specified as an ideal flooring material in sustainable buildings.

Combining environmentally friendly elements with unlimited design possibilities lends to a flooring that is as aesthetically appealing as it is practical, and that is an important aspect to be able to realize in modern design and construction.