How is Cement Tile Made?
Cement tiles from Rustico Tile are created with three layers that are visibly seen in a cross-section view of the tile.
The First Layer: The wear layer, also called the concrete tile face, is a mixture of highly resistant Portland white cement, powdered white marble and natural pigments. Wear resistance, color and brightness rely on the quality of this layer. The finished encaustic tile has the natural finish surface and these hand-crafted floor tiles can be sealed or polished.
The Second Layer: This is a mortar made of fine sand and high quality Portland cement. For tile manufacturing, this mortar is applied as a base and reinforces the first layer. It provides the ability to withstand compression loads.
The Third Layer: This final layer is a porous mixture with the required thickness for impact strength before and after installation.
A good quality concrete tile should be compact and waterproof. The tiles are made using mixtures rich in quality cement and hydraulically pressed. A thorough curing process is also implemented to fortify the cement floor tile.
Rustico Tile and Stone cement tiles can be used in residential and commercial applications including, but not limited to: hand-crafted tile flooring, wall tile, stair tile, backsplash tile, ceiling tile, on counter tops, as swimming pool tile and pool decking tile, and as fountain tile. They can be used indoors and outdoors. Cement tiles lend themselves to architectural styles such as Spanish colonial, Santa Fe, Moorish, Minimalist, Contemporary, Rustic, and Mediterranean.
The Manufacturing Process
Colors are first prepared according to the customer’s order specifications. Each encaustic tile is made individually, and slight color variations can occur. This is an inherent characteristic in cement tiles, as it is made with natural materials.
The divider is set into the mold. This is what will separate the colors to create the surface of the concrete tile. Each color is poured into its specific section of the divider. Once each color section is filled, the divider is removed and a mixture of fine sand and Portland cement is applied. This is the second layer, and is used as a drier and to reinforce the first layer of the cement tile.
Next, a porous mixture made of sand and Portland cement is applied. This is the third layer. The hand-crafted cement tiles are hydraulically pressed to give the encaustic tiles their hardness. Some cement tiles sold by other companies may just be hand-pressed, which results in a much weaker strength tile.
Finally, the cement tiles are cured under water for a 24-hour period. This finishes the hardening process. Once completed, the floor tiles are moved to a solarium to dry for another 24 hours.
After each piece is individually inspected for quality, the tiles are packaged and shipped in pallets. Recommended overage for waste, cuts and borders is 15%.
Did you Know?
Cement tiles are 100% handcrafted by talented artisans in Mexico.
Cement tiles are “green!” They are not a pollutant, because they are made with 100% natural materials, including the pigments.
Cement tiles are not flammable and are 100% recyclable.
Cement Tiles can be manufactured to any design, shape, or color. Our website just illustrates the most commonly sought after designs.
Quality control is conducted on a piece-by-piece basis, not on a lot production.
NOTE: This is hand-made, rustic cement tile. With cement tile of this nature, there will be color and texture variations from piece to piece. Color shading can vary even on a single tile. Chips or texture variations may exist. This is normal and not considered a defect for handmade tiles. It is advised to order all cement tile needed for a project. Subsequent orders can come in with shade variations. Samples of colors ordered can vary from actual shading or product received in a final ordered placed. Average lead time for most cement tile orders is approximately 4-8 weeks. Please inquire about current lead times prior to ordering.