Cement tiles have a rich history rooted in craftsmanship, tradition, and artistry. These beautiful tiles, known for their durability, intricate patterns, and vibrant colors, have been used for centuries to enhance spaces with a timeless appeal. From traditional manufacturing methods to their resurgence in modern design, cement tiles are both a historical treasure and a contemporary favorite.
A Historical Journey
Cement tiles, also known as encaustic cement tiles, first gained popularity in the mid-19th century. They originated in the Catalonia region of Spain and quickly spread across Europe and the world. In the late 19th century, they became popular in Southern France and were known as painted cement tiles. During the 20th century, cement tiles became even more widespread, used in buildings, homes, public places, and private enclaves across Europe and the Middle East. Cement tile-making had its foundations during that period due to monetary constraints.
Encaustic cement tiles have a rich history that spans centuries, and they have recently seen a resurgence in popularity among interior designers, architects, contractors, and homeowners. Encaustic tiles date back to the medieval period, around the 12th century, when they were first used in Europe. Initially, these tiles were made from clay and featured designs created by inlaying different colors of clay. During the Renaissance, encaustic tiles gained popularity in Spain, Italy, and France. These tiles were commonly used in churches, monasteries, and palaces, adding intricate and colorful designs to floors and walls.
By the 19th century, the popularity of encaustic tiles began to wane, and they were largely replaced by cheaper and more easily produced ceramic tiles. However, during the Victorian era, there was a renewed interest in medieval art and architecture, leading to a revival of encaustic tiles.
Concrete tiles first appeared in Moorish Spain around 711, featuring ornate designs and complex patterns. Cement tiles quickly became a symbol of elegance and beauty in both residential and commercial spaces. Their versatility, durability, and ability to withstand harsh weather conditions made them an ideal choice for floors, walls, and outdoor areas.
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The Art of Manufacturing
The beauty of cement tiles lies in their handmade production process. Unlike mass-produced ceramic or porcelain tiles, cement tiles are crafted one at a time, making each tile unique. Each individual handmade cement tile is unique and slight imperfections are to be expected. The imperfections give the tiles character and depth.
How Handmade Cement Tiles are Made | STAREL stones
The Cement Tile Production Process:
- Design Creation: First, a metal mold called a “divisor” is created based on the tile’s design. The metal mould is handmade from specific design drawings.
- Color Mixing: Colored pigments are mixed with white cement to create the vibrant designs. The pigment composition is a mixture of high quality white Portland cement, marble powder, fine sand, and natural mineral color pigments.
- Layering and Pressing: The colored mixture is poured into the mold, followed by a layer of cement and sand. The tile is then hydraulically pressed to ensure strength and durability. The pigment layer is hydraulically pressed into the surface and becomes a part of the tile.
- Curing and Drying: After pressing, the tiles are carefully removed from the molds and placed in a controlled environment to cure and dry. Improper curing reduces quality. Tile should be cured for 2-4 weeks before installation.
- Finishing Touches: Once cured, the tiles are inspected for quality.
Zellige Tile Manufacturing
For zellige, the highest quality of clay must be used and is found in the Fez region of Morocco. Once found, in underground mines or open pits, this clay is soaked in water until it reaches a soft texture. The clay is then filtered by hand to extract impurities like rocks and branches. After filtering, a skilled craftsmen flattens the clay into square shapes by hand, ensuring it is compact and with no air bubbles in it. After the tiles are well dried, another skilled craftsmen applies the glaze colors by hand, one-by-one, to only one side of the tiles. Once dried, the tiles are meticulously stacked in a natural olive-pit fired kiln. In these traditional Moroccan kilns heat circulates unevenly, imbuing each handmade tile with its own unique tone, texture, and color. Once fired, a skilled artisan will use a medieval tool called a ‘menkach’, a combination of an axe and hammer, to cut and shape each tile into the desired shape. This intricate process involves great patience and skill.
The Artistry Behind the Designs
Cement tiles are renowned for their intricate patterns and bold colors, often inspired by traditional art and cultural motifs. From geometric designs to floral patterns, the artistry behind these tiles reflects the creativity and skill of the craftsmen who make them.
Resurgence in Modern Design
In recent years, cement tiles have seen a resurgence in popularity, with homeowners, architects, and interior designers rediscovering their charm. Encaustic cement tiles are perfect for kitchen backsplashes and flooring. Their vibrant patterns can add personality to an otherwise neutral kitchen. In modern bathrooms, encaustic tiles can create a striking focal point. Whether used on the floor or as a feature wall, their unique patterns add depth and interest. Outdoor spaces benefit greatly from the durability and beauty of encaustic tiles. They are ideal for patios, garden paths, and pool surrounds, providing a stylish and practical solution for high-traffic areas.
One of the most prominent trends in modern design is the use of bold patterns and vibrant colors. Encaustic cement tiles are perfect for creating eye-catching designs that make a statement. Another trend is the mixing and matching of different patterns and colors. This approach allows for the creation of unique and personalized spaces. With a growing focus on sustainability in design, encaustic cement tiles are an eco-friendly choice.
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Versatility in Design Styles:
- Farmhouse Design: Farmhouse design is known for its rustic, welcoming vibe, and cement tiles add the perfect touch of charm.
- Ranch House: For a ranch house, cement tiles can bring a touch of elegance and sophistication.
- Modern Homes: In modern homes, cement tiles are often used for their clean lines and bold patterns. In modern homes, encaustic tiles can be used to create bold, graphic patterns that add a contemporary edge.
- Cozy House: For a cozy house design, soft, muted colors and floral patterns in cement tiles can create a warm and inviting atmosphere. The natural, handcrafted look of encaustic tiles complements farmhouse and rustic styles beautifully. For ranch-style homes, encaustic tiles can add a touch of elegance while maintaining the casual, comfortable vibe.
Durability and Sustainability
Cement tiles are incredibly durable and can last for decades when properly cared for. Cement tiles are made from natural materials, including cement, sand, and mineral pigments, making them an environmentally friendly choice. Cement tiles are highly customizable, allowing homeowners and designers to create unique and personalized spaces. As a result, their production has a much lower carbon footprint compared to ceramic tiles. Not only are they eco friendly, they are also incredibly durable, lasting well over a century.
Installation and Care
Proper installation and protection of cement tile is key. Please ensure that tile is laid by a licensed tile installer. Zia Tile is not responsible for any issues that arise due to improper installation or care. DO NOT LET THE BOXES GET WET! We do not recommend installing our tiles outdoors in places that experience frost/freeze in winter. Care must also be taken in areas that may get wet as the surface may cause a slip hazard. Wall tiles can be affixed to plaster, drywall, cement block, and cement backer board. The installation surface should be flat and dry with any loose paint removed and cracked surfaces patched. If the subfloor is even and in good condition, a high quality medium-bed thinset is sufficient to set the tiles. Please make sure the subfloor has completely cured (usually a minimum of 30 days) to prevent efflorescence spots from depositing on the surface of the tiles as moisture evaporates through them. Uncured or unsettled sub-surfaces can cause cracks to form in the tile as the sub-surface deforms, so always ensure the sub-surface has cured properly before installing cement tile. Use of an uncoupling membrane (such as DITRA) may also be advised. For wall installations, only install cement tile on stable, even surfaces such as cement backer board. In dry areas (i.e. kitchen backsplash), cement tile may be installed directly to drywall.
Evenly apply the thin set mixture to the subfloor using a trowel. Using only the palm of your hand, press the tiles into place. Do not use a rubber hammer or mallet as that can create small cracks that will grow over time. Place in small sections no larger than 2’x2′ at a time, and immediately wipe off any residual thin set from the surface of the tiles.
Cement Tiles must be sealed on-site. Use a pH neutral cleaner before sealing; products made to clean natural stone are usually suitable. After laying the tile and prior to grouting, apply penetrating sealer (511 Porous Plus) in thin layers until the tiles become fully saturated, wiping off any excess sealer before it dries. Do not over-seal as thick or excessive application of sealant can dry unevenly and result in an undesirable waxy film on the surface of the tiles. Using only standard, NEUTRAL, UNPIGMENTED, UN-SANDED GROUT, fill in the gaps between the tiles with a rubber grout float. Never spread dark grout over the surface of cement tile. Grout in small areas, no larger than 2’x2’, at a time. DO NOT grout the entire floor at once, as the tiles can stain from excess grout that is extremely difficult to remove later. Instead, grout small areas and immediately wipe away the excess grout as you go. Clean the tiles with pH neutral detergent, removing any residual mortar or debris. Completely clean and dry the tiles before applying a second coat of penetrating sealer over the tiles and grout. Commercial projects or clients wanting added protection may use Fila Solutions Matt Wax topical sealer 24 hours after penetrating sealer has fully cured on indoor applications only. ALWAYS cover the tiles with durable paperboard i.e. Over time, cement tile wears like a natural stone product, which is part of the appeal of this old-world tile.
Cement tiles are easily cared for wash with mild detergent (E.g.: neutral soap, Murphy soap) and water. Never clean with harsh detergents, acid or alkaline, it will irreversibly damage the tile surface. The toughest stains can be smoothed out by scrubbing with an soft abrasive like Scotch Brite. Avoid scrubbing with hard abrasives that can remove the finish and damage the pigment layer of the tile.
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