Topic outline

  • Tile Manufacturing

    TILE MANUFACTURING (AZULEJOS)

    This course introduces in a concise way and with practical examples an approach to the universe of tiles from its manufacture to its diverse use. It is intended to make known all the processes involved in the manufacture of tiles; from the raw material to the manufacture and painting, as well as the placement of the tiles on the wall. The tile is an architectural element linked to the history of Portugal that gains great prominence especially from the sixteenth century, and that comes to this day, is present everywhere and constitutes an important link of transmission between generations. It belongs to a family of other decorative objects, along with a variety of functions that the tile plays in civil and religious society.

    Through this set of videos, the aim is to present all phases of the manufacturing process of the tile, and to show all the equipment necessary for the proper execution of this ceramic product: types of body, preparation, cutting, shaping and painting of tiles; colours, glazes, glazing and firing; traditional mortars, kilns and laying on masonry. Bearing in mind that the role of the producer of manufactured tiles is also related to the safeguarding of the built heritage, and to the maintenance and restoration of existing panels, we make a short approach to the problems of tile conservation. We present methods of diagnosis and survey, treatment and laying. We talk about criteria and products for intervention.

    This course is composed of a total of 9 films, with images of practical examples, accompanied by the appropriate explanations. A last film will deal with the issue of conservation of the tile heritage, with a sampling of certain technical procedures. A fundamental requirement for the execution of tiles is to have a set of equipment. It is essential to have access to a ceramic kiln and facilities that provide adequate working space and comfort. The manufacture of ceramics in general and of tiles in particular is a task with many nuances and small variables that condition and mark the final work. But with dedication everything is achieved, and the effort makes the work much more rewarding.

    Master of the course: António Jorge Cruz, artisan (Portugal)
    Format of the modules: 9 pieces of video tutorials, subtitles and text-form descriptions
    Full playtime of tutorial videos: 55 minutes 11 seconds

    • Part 1

      • Tutorial Video - 1 Page
        Pigments, oxides and glazes I
        Identification, preparation and application of pigments and glazes

        Shortfilm - Length: 17 minutes 15 seconds
        Original language of the film: Portuguese
        Subtitles: English, Estonian, Hungarian, Lithuanian, Portuguese, Swedish, Romanian

        This module aims to show the painting process using natural pigments.

        Learning objectives:

        • understand and distinguish the existing types of pigments.
        • get to know some of the pigments used in tile painting.
        • identify the main oxides and types of glazes used to colour pastes, under or over glazes and to colour glazes.
        • understand the difference between painting and inking.
        • define what glazes are and what kind of materials are used in glazes.
        • indicate the differences between glazes and glazing paints.
        • identify some of the common metal oxides.
        • classify the variation of the oxides according to the cooking temperature.
        • identify low temperature pigments, with an extended colour palette.
        • identify the different types of pigments (high temperature pigments, inorganic and non- volatile pigments, reactive pigments). ... MORE >>

    • Part 2

      • Tutorial Video - 2 Page
        Pigments, oxides and glazes II
        Identification, preparation and application of pigments and glazes

        Shortfilm - Length: 4 minutes 18 seconds + 6 minutes 56 seconds
        Original language of the film: Portuguese
        Subtitles: English, Estonian, Hungarian, Lithuanian, Portuguese, Swedish, Romanian

        This module continues the previous one by showing some more variety in tile painting and the application of coloured glazes.

        Learning objectives:

        • know the properties of oxides (solubility, thermal stability, physical and chemical resistance, granulometry).
        • understand what they are glazed over.
        • identify the most common components in glazing and glaze tiles.
        • describe the relationship between the melting temperatures and the glazing of the tiles.
        • classify the glazes according to their gloss, transparency, firing temperature (high or low fire), preparation and composition.
        • mention the desirable properties of glazes (fusibility, firing temperature, expansion coefficient and its relationship with the clay, chemical stability, mechanical resistance to physical stress and abrasion). ... MORE >>

    • Part 3

      • Tutorial Video - 3 Page
        Manufacturing and types of tiles

        Shortfilm - Length: 16 minutes 38 seconds
        Original language of the film: Portuguese
        Subtitles: English, Estonian, Hungarian, Lithuanian, Portuguese, Swedish, Romanian

        This module aims to present the traditional methods of manufacturing tiles. The ballast. Some types and dimensions, plain, beveled and relief. Shaping, shaping, cutting and drying. Understanding the general process: removing impurities; drying (losing excess water); kneading; shaping and unmoulding; 2nd drying; 1st firing (filling); glazing; colouring process (optional); 2nd firing (final)

        Learning objectives:

        • understand how the clay is prepared: The excess water is removed and the clay is kneaded until it has the desired consistency.
        • know the process of kneading the clay. Weaving the paste, rolls and types of pelas, The ballast, the rolled out dough and the moulds.
        • know the differences in the size of the moulds and the final dimensions of the fired tile.
        • know how tiles are cut with squaring moulds and presses.
        • understand the importance and process of drying and turning the pieces.
        • know how to apply moulds for the relief tiles, the process of removing the tile from the moulds.
        • know how to cook and the right temperatures for pastes.
        • know what the mockery is.
        • understand the application of glazes.
        • know traditional hand glazing processes: the bowl process, the spade process and the brush process. ... MORE >>

    • Part 4

      • Tutorial Video - 4 Page
        Preparation and painting of traditional motifs

        Shortfilm - Length: 10 minutes 11 seconds
        Original language of the film: Portuguese
        Subtitles: English, Estonian, Hungarian, Lithuanian, Portuguese, Swedish, Romanian

        It is intended to show some types of painting on ceramics and tiles: know the most used variations, hand-painted, stamped, old techniques, dry string and edge, boxed, figurative, vegetal, pattern, etc..; pigment dyes, glazes, etc.; see some examples and the various glazin techniques. Firing. Kilns and firing accessories: gazettes and trivets. Colouring the tile can be done with pigments, stains, glazes or glazes. Taipal, vertical support for manual and artistic painting.

        Learning objectives:

        • know the basic process of tile painting: painting on chacota and painting on raw glaze.
        • learn about lead and tin frit enamels.
        • to understand how representations are made on tile panels based on engravings: drawing passed onto paper by means of a grid; the method of transferring the outlines with charcoal powder by means of the perforation (estresido).
        • understand how to make outlines freely made with a brush in one colour, outline of the drawing made with a pencil.
        • know brush painting, brush qualities.
        • to perceive variations in the thickness of pigments, in monochrome painting, or to simulate volumetry.
        • Know the technique of sponging, sgraffito and spraying paint to create textures.
        • to understand the varied and possible configurations between glazing and painting and enamels, painting after raw glazing with enamel paint or only pigments.
        • Paint over clear coat, or enamels.
        • know the differences between paints made with pigments or dyes.
        • know how the tiles are placed in gazettes made of refractory clay so that they can withstand high temperatures, inside the muffle. ... MORE >>

    • Part 5

      • Tutorial Video - 5 Page
        Masonry and mortars for tile setting
        Preparing the masonry, and types of mixtures in the composition of traditional mortars

        Shortfilm - Length: 11 minutes 3 seconds
        Original language of the film: Portuguese
        Subtitles: English, Estonian, Hungarian, Lithuanian, Portuguese, Swedish, Romanian

        This module aims for the student to get acquainted with the preparation of walls and masonry, and with the types of mortars used.

        Learning objectives:

        • know the general components of mortars: binders and aggregates.
        • to know traditional mortars, their composition and the advantages of traditional mortars compared to cement.
        • know what "poor" mortars are.
        • knowing the traditional predosed, applied mortars: what are the advantages of knowing the historic mortar types according to the region where they are used.
        • know how to prepare a wall, do levelling and know the material and equipment;
        • know the composition and how to execute the "traces"; binders, hydraulic lime and aerated lime, sand and water.
        • know the types and usefulness of contemporary adjuvants in mortar mixing: cement- glue, aqueous dispersion adhesives, and chemical reaction adhesives.
        • know the recommended thicknesses when applying the support.
        • knowing the surface of the plastered masonry for the application of tiles, understanding the problem of compatibility with the ceramic bodies of the tiles, the degree of thermal expansion and moisture retention, the degree of porosity and other appropriate considerations.
        • understand the process of mixing mortar and know the appropriate equipment and material for mixing and applying mortar. ... MORE >>

    • Part 6

      • Tutorial Video - 6 Page
        Application/Setting of tiles on support with traditional mortar

        Shortfilm - Length: 11 minutes 1 seconds
        Original language of the film: Portuguese
        Subtitles: English, Estonian, Hungarian, Lithuanian, Portuguese, Swedish, Romanian

        The aim is to show the technique of laying tiles on a wall support.

        Learning objectives:

        • know how to lay tiles.
        • know how to apply mortar, materials and equipment.
        • understand how to prepare the walls, do the preliminary cleaning, the levelling of cracks and gaps, the moistening of the support or plaster.
        • realize the need to allow a drying time between the application of the plaster on the substrate and the application of the laying mortar.
        • knowing how to prepare mortar, care with the amount of water.
        • understanding the process of tile laying: placing of master guides and marking the joints, laying sequence, laying the tiles before placing them in the previous sequence (the importance of the photographic record), having the tiles labelled in a sequence, the importance of replicas before applying (dampen previously), application of mortar on the back and support, pressure and the use of the rubber hammer.
        • understand the importance of choosing the start of the laying, from the left to the right of the first row, or from the centre to the sides.
        • know what the joints are: the dimensions of the joints, which must correspond to the original joints, and the joint mortar for finishing.
        • knowing methods of applying mortars, auxiliary resources for controlling the laying, different mortars for different moments of the laying. The trait, the bastard or poor mortars and mortars with cement mixtures. Exceptional cases and conditions of use.
        • know the right equipment: gloves, spoon, troughs, rubber hammers, etc. ... MORE >>

    • Part 7

      • Tutorial Video - 7 Page
        Historic tiles: most common pathologies and conservation problems
        Identification of agents and mechanisms of degradation. Mapping pathologies in historic buildings.

        Shortfilm - Length: 7 minutes 8 seconds
        Original language of the film: Portuguese
        Subtitles: English, Estonian, Hungarian, Lithuanian, Portuguese, Swedish, Romanian

        This module aims to raise awareness of conservation issues. Know the main causes of degradation: environmental, manufacturing, chemical, physical and biological.

        Learning objectives:

        • understand the need for a pathology register and give an example of how to do it.
        • know different pathologies: manufacturing defects (quality of materials, drying, etc.); laying defects (poor quality of mortar or of the laying process); defects of the building construction or of the architectural support (structural variations); humidity and temperature fluctuations (location and solar orientation); humidity conditions (presence of water by salts and capillarity and salts); presence of micro and macro- organisms, dirt, etc.; Recognise anthropic factors (human action, restorations applications of incompatible materials, vandalism)
        • Identify the pathologies of the support: cracking. Mortar: detachment and detachment, blistering of panels, detachment, joint splitting and disintegration. Glazed tiles: detachment, detachment, cracking, detachment of the glazing, craquelet, wear and disintegration of the cladding or glazing.
        • understand the need to record and map the pathologies of the tile panels and their main coordinates: location and description of the implementation, documentary research, establishment of various records of building, mortar and tile, general and detailed record of pathologies, labelling of the units (tiles) (survey by quotas, marking of coordinates, and graphic record in digital support and subtitling of pathologies.
        • to have a notion of what a diagnostic file is: elements such as location and owner, description, (typology, chronology, materials, dimensions, pathologies (description and location of pathologies.)
        • knowing the photographic and graphic register, complementary analyses (mortar composition, chacotte and glazes, etc.) ... MORE >>

    • Part 8

      • Tutorial Video - 8 Page
        Conservation and restoration of ancient tiles. Manufacture of replicas.

        Shortfilm - Length: 12 minutes 4 seconds
        Original language of the film: Portuguese
        Subtitles: English, Estonian, Hungarian, Lithuanian, Portuguese, Swedish, Romanian

        Short approach to conservation and restoration. Stages of diagnosis.

        Learning objectives:

        • identify the need for in situ treatment or removal of the tiles from the support.
        • know how to start a graphic and photographic record, and mark the units.
        • how to make a facing, understand its usefulness.
        • understand how each unit is cleaned (removal of mortar from the back, cleaning of grease, various types of dirt, biocolonisation, etc.).
        • understand the physical-chemical and mechanical stabilisation process: consolidation, adhesive bonding, gap filling and levelling.
        • know about colour reintegration, and the protection of the treatment.
        • know cleaning materials, adhesives and consolidants, thinner and solvents. ... MORE >>

    • Part 9

      • Tutorial Video - 9 Page
        Observation of a tile restoration in laboratory

        Shortfilm - Length: 16 minutes 51 seconds
        Original language of the film: Portuguese
        Subtitles: English, Estonian, Hungarian, Lithuanian, Portuguese, Swedish, Romanian

        Detailed observation of a tile restoration. Capture the phases of intervention and the procedures in sequence. Use of appropriate equipment and materials.

        Learning objectives:

        • to know the intervention process: cleaning, eventual desalination, consolidations, adhesive bonding, fillings, chromatic reintegration, varnishes and finishes. The equipment, materials and products.
        • know the equipment and auxiliary materials: lights, magnifying glasses, binocular magnifying glasses, scales, desiccators, vacuum chambers, vats, brushes, blades and scalpels, needles, laboratory material; the various types of adhesives, varnishes, waxes, resins and binders; solvents, reagents; inks and pigments; paint brushes and airbrushes; products for moulds, fillers, finishers and mortars.
        • It is intended that the student is aware of the most general procedures of tile restoration.
        • It is intended that the student knows and recognizes the ceramic material in order to be able to make an intervention in a damaged piece using the most appropriate resources.
        • It is intended that the student understands that it is possible to recover damaged tile elements in a simple way using contemporary resources and cold without the need for an oven. ... MORE >>

    • EXAM