Spec

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About the company

• Specific Ceramics Ltd is engaged in the business of manufacturing quality floor glazed and unglazed vitrified tiles by the brand name Durato.

• Specific began with a view to manufacture tiles that blend design with technological expertise and with the purpose of customizing cost-effective solutions for the specific requirements of architects, interior designers, builders, and individual end customer.

• We are proud that the Company’s collaboration is with global trends. This is what inspires innovation, generates research, and propels and regulates our quality standards.

The Plant

• Specific’s plant is located at Karoli, in Kalol Taluk of Gandhinagar District & 15 km away from Ahmedabad. It is one of the fastest growing and well equipped industrial complexes in Gujarat having complete infrastructure with global IT and telephone networks.

Technology & Knowhow

• The company is staffed with highly qualified Research scientist, ceramic engineers and technicians, with well over 20 to 25 years proven track record in the manufacture of ceramic bodies, glazes, pigments and frits.

• They are well versed with new advances in ceramic technology, modern applications and the latest innovations and developments in raw materials and machinery.

Choice of raw material

At Specific Ceramics ltd - Raw materials are selected on the basis of Material cost, Market factors, Vendor services, Technical processing considerations, The ultimate performance requirements and Market price of the finished goods.

VITRIFICATION

Sources of the clays

Specific Ceramics uses high quality and more expensive fine clays to ensure that its product surpass the stringent specification of BIS & EN standards for vitrified tiles.

Mines are well inspected and samples collected from time to time to check for consistency in supply.

The raw clay is extracted selectively, whereby different qualities are sorted out and used as white firing, yellow firing or red-firing raw materials.

Clay Mineralogy•Below is an introduction to clay mineralogy.

• Clay minerals are an important group of minerals because they are among the most common products of chemical weathering, and thus are the main constituents of the fine-grained sedimentary rocks called mud rocks (including mudstones, claystones, and shale's).

• In fact clay minerals make up about 40% of the minerals in sedimentary rocks.

•In addition, clay minerals are the main constituent of soils.

•Understanding of clay minerals is also important from an engineering point of view, as some minerals expand significantly when exposed to water.

•Clay minerals are used extensively in the ceramics industry and are thus important economic minerals.

•Based on their structures and chemical compositions, the clay minerals can be divided in to four main classes:

(Some Clay Scientists refer to 2 or 3 classes for clays: Chlorite is sometimes referred to as a 2:1 layer not a 2:1:1 and Illites/Micas are sometimes grouped with Smectites)

•Kandites 1:1 layered clays eg) Kaolinite

•Smectites 2:1 layered clays eg) Montmirrilonite

•Illites/Micas 2:1 layered clays eg) Muscovite

•Chlorites 2:1:1 layered clays eg) Clinochlore

The Kandites

Above is a model of a Kaolin Crystal viewed from different angles, showing its structure. Kaolin minerals form plate like structures which are visible by Electron Microscopy.

The Kaolinite family of Clay Minerals are formed by weathering or hydrothermal alteration of aluminosilicate minerals. Because of there chemical weathering resistance and non-swelling nature they are the clay of choice in ceramics and porcelain products.

The Smectites

Above is a model of a Smectite Crystal viewed from different angles. The Interlayer space can clearly be observed and this accounts for the swelling

nature of smectites.

Smectite rich soils can undergo as much as a 40% volume change due to water being absorbed and desorbed in Interlayer space. The force behind this

swelling is immense,and can raise buildings and structures by a few centimetre's causing cracks and other problems.

The Illites / Micas

Above is a model of a Muscovite Crystal (a good example of an Illitic/Micaceous Mineral) viewed from different angles, showing its structure.

Illitic/Micaceous Clays or a major component of Ball clay, and as such have a major use in the ceramic and clay brick industry. Although Illites have a interlayer space, the attraction between the 2 plates is extremely strong, and prevents Illites/Micas from swelling, when in contact with water .

The Chlorites

Above is a model of a Typical Chlorite Crystal viewed from different angles.

Chlroritic clay is mainly associated with Illitic/Micaceous Clay and as such is used in the ceramic industry .It is easily weathered into other clay minerals,and as such is the least occuring clay mineral .In fact deposits of predominantly chlorite clay have yet to be discovered.

Pictures of Kaolinite and Illite

Below are Scanning Electron Microscope Pictures of Kaolinite Interstratified with Illite. Note the platelets of Kaolin are easily observed.

XRD Scan Comparison Fired Clay

X-Ray diffraction is a powerful tool in all mineralogical work,Below is an example of comparative XRD scans showing the change in Raw clay compared to Fired Tile. Clay was fired at 1150 Celsius for 25 minutes.

Notice the clay peaks(Illite at 8.9 ,and Kaolinite at 12.3 Degrees 2 Theta have disappeared and a new peak at 16.5 Degrees 2 Theta has formed.

This new peak is the mineral Mullite. Mullite is what forms when clays are fired and is the mineral we associate with ceramics.

Feldspar :• Feldspars are alumino-silicate minerals found in nearly all igneous rocks.

• They have very similar chemical compositions, e.g.

• Potash feldspar or orthoclase K2O.Al2O3.6SiO2

• Soda feldspar or albite Na2O.Al2O3.6SiO2

• Lime feldspar or anorthite CaO.Al2O3.2SiO2

• Feldspars are used as a flux in the firing of ceramic body.

• When a body is fired, the feldspar melts at a lower temperature than clay or

silica, due to the presence of Na+, K+ or Ca2+ ions, and forms a molten

glass which causes solid particles of clay to cling together.

• when the glass solidifies it gives strength and hardness to the body.

• The molten glass also reacts with the silica and clay particles.

This photo shows a large plagioclase grain which is easily identified by the twinning in the photograph with polars crossed.

This photo shows a pebble-sized fragment composed almost entirely of microcline. Microcline can be identified easily by the cross-hatched twinning which it invariably shows.

Product Introduction

• Durato is a compacted vitrified product of mixtures of clay, quartz and feldspar.

• Durato’s microstructures are grain and bond type with large particles of filler (usually quartz) held together by a finer matrix, which is almost fully dense.

• Because of the complex interplay between raw materials, processing routes and approaches, and the

kinetics of the firing process, Durato formulations represent some of the most complicate ceramic systems

Here we see grains of Silica (quartz) and soda –aluminate crystals (plagioclase) in a matarix of finer quartz and K-feldspar. The largest grain is quartz and appears to be split along a fracture in the XP view. Many other, smaller, quartz grains are also present. A single large grain of plagioclase can be identified by its zebra-stripe twins (XP). 

Technical Performance

• The required technical performance of durato tiles is associated with their dimensional parameters, mechanical strength, water absorption, chemical stability and wear resistance. These are largely dependent on microstructural characteristics such as porosity.

• The final microstructural features of the durato tiles are developed during processing and consolidated in the firing stage, in which physical and chemical reactions occur among the different constituents.

SEI of unetched P700, showing a-quartz grains (“Q”), clay relict

agglomerates (“C”), and feldspar grains (“F”).

CERAMIC TILE MANUFACTURING PROCESS

The ceramic tile manufacturing process consists of a series of successive stages.

1.Raw materials preparation

2. Pressing and drying of the green body

3. Firing, with or without glazing

4. Additional treatments

5. Sorting and packing

SEI of (a) etched P1400, showing bubbles formed on overfiring,

Schematic illustration of the micro structural evolution in vitrified tiles.

Some doubts

and

clarifications

about vitrified tiles

and

ceramic tiles

What are the differences between ceramic tiles and vetrified tiles? What are the advantages of vetrified tiles over ceramic tiles?

• Ceramic tile has become the general term given to most tiles that are made from clay products.

• Ceramics include porcelain and 'gres' tiles too. Ok, the difference.• It has to do with how hard and dense the body (bisque) is after firing.• Regular ceramic can be pretty soft and absorbant.• Gres is dense and frost resistant or frost proof, and porcelain is very

dense and frost proof.• Ceramic and gres is glazed, porcelain is often unglazed, and the same

color thru out. Many porcelain tiles however are 'porcelenato' which have a glaze for easier maintenance.

• Vitrified tiles are 'glass-like'. Vitro means glass in Italian. So vitrified tiles are hard and frost proof. Although only a small amount of tiles are used outdoors in cold weather service, people buy them cause they are stronger than regular soft cheap ceramic.

What is a vitrified Tiles?

• Vitrified Tiles consists of a spray dried body of selected clays, kaolinitic minerals, quartz and feldspar, shaped by dry pressing to form a ceramic material that is then fired at temperatures up to 1250 degrees centigrade.

• A key element of vitrified tiles is its extremely low level of water absorption which is below 0.5%.

• As a result of new innovative processes new vitrified tiles bears a striking resemblance to natural stones such as marble and granite.

Where can vitrified tiles be used?

Vitrified is ideal for :• interior and exterior floors and walls • Facades of buildings. • It is available in natural, smooth, polished

and structured finishes.• Vitrified tiles is an ideal material for use in

the creation of dynamic water jet designs .

How are the Anti-Slip ratings of tiles calculated?

• The various working areas are classified in five groups, according to the danger of slipping up in them.

• To determine in which of these groups a material should be classified, it is applied on a surface that is gradually sloped.

• A person wearing shoes walks up and down the slope until he starts slipping.

• The value in degrees of the slope reached before he starts slipping determines the classification of the material in class:

• R9 slip start value less than 10 degrees (mimimal friction) • R10 slip start value from 10 to 19 degrees (normal friction) • R11 slip start value from 19 to 27 degrees (good friction) • R12 slip start value from 27 to 35 degrees (high friction) • R13 slip start value more than 35 degrees (very high friction)

Is it risky to choose tiles based on photos in a catalogue

rather than on tile samples?

• We have all seen how photographs reproduced in printed publications such as catalogues provide an image of an object (in our case a tile) which is faithful but not identical to the original, detailed but not necessarily complete.

• In other words, if we place a tile alongside a photograph and observe closely, we will see that the printed colour, although very similar, is perceptibly different.

• Even more importantly, the surface may have a gloss finish or texture that is not effectively conveyed by the printed reproduction.

• For this reason, it is advisable to use a catalogue to make a preliminary selection of several tiles, then use samples of the tiles to make the final decision.

• Another important point concerns the fact that the batch of tiles you receive will have a given colour tone as specified on the box.

• It is important to check that all the tiles in the batch you have purchased have the same colour tone.• In their warehouses the manufacturer or dealer will have batches of tiles of the same type that you have

chosen but with slightly di fferent colour tones. • These differences in tone are an inevitable result of the technological characteristics of the production

process. • This has no adverse consequences for the user provided a batch of tiles with the same tone is used for a

specific installation.• It doesn't matter if the tone of the batch is not identical to that of the sample used for choosing the tiles as

the differences in tone are so small that they are visible only when two tiles are placed alongside each other.

Grading

• In the United States there are five grades assigned to floor tiles, whether they are imported or produced in this country. The grades are in Roman numerals, with grade I being the lowest and V the highest. I know of no one who makes grade I tiles however, so let's start with II.

• Grade II tiles can be used in residential applications where light traffic is expected. Bathroom floors, for example, do not receive very heavy traffic.

• Grade III tiles are adequate for any residential use, including kitchen and entry floors, which receive considerable traffic. These tiles might also be used in light-traffic commercial applications -- perhaps beauty parlors and other businesses where there is nota heavy and continuous volume of foot traffic..

• Grade IV tiles are rated commercial, although they are also commonly used in homes. These tiles will hold up in just about any application, including grocery stores, bank lobbies, etc.

• Grade V tiles are used in industrial settings, where they are expected to receive heavy abuse and exposure to various chemicals. Not many grade V tiles would be used in the home. They usually look too commercial.

• Tile grades are never stamped on packaging, so you are at the mercy of the person selling you the tile.

What are the technical characteristics of vitrified tiles?

Vitrified is resistant to :• wear• deep abrasion• and frost.• It is a practically non-absorbent material with great

flexural strength. • Quality durato will remain constant over time.

STAGES OF TILE MANUFACTURE

The raw materials are loaded by pay loaders

into the box feeder according to the batch recipe

STAGES OF TILE MANUFACTURE

The raw materials are milled in large ball mills

And converted into slurries

High powered Electro magnet

The high powdered electro magnet is used to remove the

iron specks thus making the tile absolutely spot free.

Durato’s are being sprayed to

protect from stains and dirt

STAGES OF TILE MANUFACTURE

One the longest two tire drier enabling the tile to achieve excellent green strength and free of cracks

of

Two tire Dryer

The tiles are fired at temperatures of 1200°C to 1220°C in roller hearth kilns.

The Roller Hearth Kiln

One of the significant factor is that specific ceramics possess the longest Kiln in Asia. It means good vitrification and very high Breaking strength.

A section of the pre - heating zone

The Roller Hearth Kiln

The plant is equipped with the latest machineries to manufacture state of the art world renown exclusive and innovative products

The Decorating & Printing Lines

They are then polished and cut

as per the requirement.

The Lab Press

The Lab testing equipments

IS 13711: 1993 Ceramic tiles – sampling and basis of Acceptance

IS 13712: 1993 ceramic tiles- Definitions, Classifications, Characteristics and Marking

IS 13756:1993 Dust pressed ceramic tiles with low water absorption of E3% (Group B I) – Specification

IS 13755: 1993 Dust pressed ceramic tiles with water absorption of 3 % < E 6 % (Group B IIa) – Specification

IS 13754: 1993 Dust pressed ceramic tiles with water absorption of 6% < E 10% (Group BIIb) – specification

IS 13753: 1993 Dust pressed ceramic tiles with water absorption of E > 10%(Group B III) – specification

IS 13630 (Part 1): 1993 Ceramic tiles – methods of test – Determination of dimensions and surface quality

IS 13630 (Part 2): 1993 Ceramic tiles – methods of test – Determination of water absorption

IS 13630 (Part 3): 1993 Ceramic tiles – methods of test – Determination of moisture expansion using boiling water – Unglazed tiles

IS 13630 (Part 4): 1993 Ceramic tiles – methods of test – Determination of linear thermal expansion

IS 13630 (Part 5): 1993 Ceramic tiles – methods of test – Determination of resistance to thermal shock

Indian Standards

WHAT IS "WATER ABSORPTION"?

•The "water absorption" is the quantity of water which a tile can absorb under particular conditions.Porcelain tiles have the lowest water absorption of any type of ceramic tile.Some characteristic which depend on the porosity of the material are the following: abrasion resistance, which increase as water absorption decreases; frost and chemical resistance.

WHAT IS "FLEXURAL RESISTANCE"?

The "flexural resistance" is a parameter characteristic of the material and corresponds to the maximum stress per unit area that a specimen can withstand without breaking when it is subjected to an increasing load.

WHAT IS "ABRASIVE HARDNESS"?

• The "abrasive hardness" is the resistance of the surface itself to wear caused by the movement of bodies, surfaces or materials in contact with the tile.

• Among these actions even cleaning and maintenance of the tile surface could be sources of abrasion due to the movement of bodies on the tile surface.

• Abrasive hardness is one of the most important characteristic considering the durability of the tile.

Classification of Ceramic TilesClassification of Ceramic Tiles

Classification of ceramic tiles according to their groups and their specific product standard.

Shaping Water Absorption

Group I

E 3%

Group IIa

3%< E 6%

Group IIb

6%<E 10%

Group III

E>10%

A (Extruded )

Group AI Group AIIa Group AIIb Group AIII

B (Dust Pressed)

Group BI Group BIIa Group BIIb Group BIII

C (Cast Tiles)

Group CI Group CIIa Group CIIb Group CIII

Group BI Group BIIa Group BIII

European StandardsEuropean StandardsEN 87 Ceramic Floor and wall tiles – Definition, classification, characteristic and markingEN 98 Ceramic tiles – Determination of dimensions and surface qualityEN 99 Ceramic tiles- Determination of water absorptionEN 100 Ceramic tiles – Determination of modulus of ruptureEN 101 Ceramic tiles – Determination of scratch hardness of surface according to Mohs.EN 103 Ceramic tiles – Determination of linear thermal expansionEN 104 Ceramic tiles – Determination of crazing resistance – Glazed tilesEN 122 Ceramic tiles - Determination of chemical resistance – Glazed tilesEN 154 Ceramic tiles - Determination of resistance to abrasion – Glazed tilesEN 159 Dust pressed Ceramic tiles with water absorption E>10 % - Group B IIIEN 163 Ceramic tiles – Sampling and basis for acceptanceEN 176 Dust pressed ceramic tiles with low water absorption (E≤ 3 %) – Group B I)EN 177 Dust pressed ceramic tiles with water absorption of 3 % ≤ E ≤ 6% (Group BIIa)EN 178 Dust pressed ceramic tiles with water absorption of 6% ≤ E ≤ 10 % (Group BIIb)

Laboratory test instruments

Nano coat vitrified tiles are coated with a special nano glaze substance which gives them brilliance, smoothness and a pleasant look.

Nano coat vitrified tiles are subjected to special drying and firing processes that necessitate a temperature of 1220C. Nano coat vitrified tiles are therefore aesthetically striking, forming an image of functionality and naturalness that is typical of granite and marble.

Their level of resistance to abrasion is such as to guarantee almost unlimited durability.

Nano Ceramic Coatings

Scratch & Abrasion Resistant

Water Repellent

Dust Repellent UV Protection Anti-sticking

Anti-Bacterial

Anti-Corrosive

Benefits and Advantages

Easy Clean Abrasion Resistant

Durato vitrified Tiles are :

1. Clay composite based that are denser and more compact.

2. Water absorption lower (less than or equal to 0.05% )

3. Firing temp higher at 1200 to 1500 deg c.

4. More compact and have higher mechanical strength.

5. Surface are polished or semi-polished.

6. Nano coated.

Subfloor preparation for Durato Tiles:To accomplish satisfactory installation, the sub floor must beStructurally sound, rigid, smooth and flat.Free of waxy/oily films, curing compounds.

FLOOR LAYOUT FOR Durato TILES :The room is squared off, measured and chalk lines are snapped. Once in place, lay loose tiles across the floor in both directions to balance the room so that the cut –tiles are of the same size on each wall.

PREPARING DURATO TILES FOR LAYING:Slight tone variation can be prevented from being a problem by mixing the tiles from several cartons before installing. This aids blending of shades.

SPREADING THE THIN-SET:Using the chalk lines as a guide, apply the thin-set on one section at a time. Spread one coat using the flat side on the trowel and then immediately come back with a second coat, using the notched side of the trowel.

LAYING TILES:The tiles are then placed one at a time on the thin-set using twisting and pressing motion, while allowing suitable spacing for the grout.

TAMPING:

Using a rubber mallet tamp the tiles to assure good contact with the thin-set.

GROUTING DURATO TILES:

Preferably done the following day, the grout is applied over a small section at a time and is spread with a sponge or a squeeze. Rub the grout firmly over the surface to push the grout into the joints. Remove off the excess with a clean damp sponge after approximately ten minutes.

Clean and sweep your tiles regularly.To remove stubborn spots, scrub with a paste of bicarbonate of soda and water.Use just a few drops of soap-less detergent. Don’t use abrasive cleaners.Vacuuming is a great way to clean tiles. Vinegar mixed with warm water is a proven and natural cleaning agent.If you ever need to use a stronger cleaner make sure it is neutral I.e. non- acidic and non-alkaline.For solid areas you can use an all-purpose household cleaner or a cleaner made specifically for ceramic tiles.Remove soot from kitchen tiles with a mixture of lemon juice and salt, then wash.

Before cleaning bathroom tiles, run the shower on hot for five minutes to steam the dirt loose. For stubborn stains, apply a paste of scouring powder and water and let sit for five minutes.

Scrub with a nylon scrub pad, rinse and wipe dry.

To keep the grout joints on tile counter tops clean longer, wash with a solution of 1-2 tablespoons chlorine bleach in one quart of water. Dry thorou- ghly, then apply an acrylic sealer or three coats of lemon oil. Let dry for one hour between coats.

Remove mildew and make tiles sparkle by sponging with a solution of ammonia and water.

Do not use soap on the tiles because it leaves a film which dulls the surface.

Do not use steel wool pads or similar abrasive cleaning pads. Loose particles of steel can cause rust stains in grout.

Do not use acid based cleaners. They can affect the colour of the grout and can cause tiles to dull. You should not use pure vinegar which is an acid.

Do not wear spiked shoes if you have high gloss floors.

Use good mats at doorways to keep out sand, which may scratch tiles.

Use buffers under any furniture which may damage the surface of the tiles.

BIS Standard test

Chemical Resistance Tests

Chemical Strength Time Temp Time Temp

Acetic Acid 10% 16 hrs 100 Deg

C itric Acid 10% 16 hrs. 100 Deg C

Detergent ---- 48 hrs 60 Deg C

Hydrochloric Acid 50% 48 hrs 25 – 35 Deg C

Sodium Hydroxide 5% ½ hrs 60 Deg C

Sodium Stearate 0.15% 48 hrs 60 Deg C

Sulphuric Acid 3% 16 hrs 100 Deg C

BIS standard stain chemical test

According to BIS standard stain chemical tests were performed on the tiles.

The following stain chemical tests were done:

1. 0.5% Methyl Blue Soln.

2. 10% Sodium Hypochlorite

3. 3% Hydrogen Peroxide

4. Amyl Acetate

5. Carbon Tetrachloride

6. Iodine with ethanol

No stain observed on the nano coated vitrified tiles.

17/01/2010

s no. CharacteristicsMETHOD OF TESTING VITRIFIED EN-176 B I a

EN ISO

1 Deviation in length EN 98 ISO 10545-2 max +/- 0.5%

2 Deviation in thickness EN 98 ISO 10545-2 max +/- 5.0%

3 Straightness of sides EN 98 ISO 10545-2 max +/- 0.5%

4 Squareness EN 98 ISO 10545-2 max +/- 0.6%

5 Surface flateness EN 98 ISO 10545-2 max +/- 0.5%

6 Water absorption EN 99 ISO 10545-3 E < 0.05%

7 Scratch resistance EN 101 ISO 10545-7 min - 6

8 Abrassion resistance EN 154 ISO 10545-7 NA

9 Deep abrassion resistance EN 102 ISO 10545-6 max. 205 mm2

10 Crazing resistance EN 105 ISO 10545-11 NA

11 Chemical resistance EN 122 ISO 10545-13resistance to all acid and alkalies with the exception of hydro fluoric

acid and its compounds

12 Thermal shock resistance EN 104 ISO 10545-9 resistant to 10 cycles

13 Bending strength EN 100 ISO 10545-4 E > 350 kgs/cm2 (35 N/mm2)

14 Impact resistance EN 103 ISO 10545-5 no indentation or cracking

15 Frost resistance EN 202 ISO 10545-12 frost proff

16 Cofficient of friction - ISO 10545-17  

17 LT Expansion EN 103 ISO 10545-8 9x10-6 K -1

18 Bulk density - ISO 10545-3 > 2 gm/cc

19 Stain resistance - ISO 10545-14 resistant min class- 2

20Moisture expansion

(seepsge resistance)- ISO 10545-10 nil

21 Colour resistance - DIN - 51094 no damage

22 Resistance to house hold chemicals - ISO 10545-14no sample must show visible

signs of chemical attack