Clay roof tiles bear a rich history which dates back thousands of years to ancient civilizations like the Chinese, Greek and Roman civilisations, where they were utilised as durable, fire-resistant materials for roofing. The natural composition of the tiles combined with longevity and aesthetic appeal make them a staple in architecture. Moreover, the use of these eco-friendly roofing solutions continues to evolve over time.
They are a popular roofing solution even in the modern construction industry. Though today’s manufacturers apply modern and advanced techniques, the manufacturing process remains rooted in traditional methods. Enhanced by technology, the manufactures ensure that the clay tiles are more durable and resistant to extreme weather conditions while maintaining their rustic charm.
This blog delves into the details of the clay roof tiles manufacturing process. From sourcing of raw materials to the final quality checks, it highlights the blends of traditional techniques and modern advancements that lead to the production of high-quality terracotta tiles.
What are Clay Roof Tiles?
Manufacturers make the clay roof tiles from natural clay, shale or other similar earthy materials. They mould, bake and sometimes glaze the tiles to create sturdy and durable tiles. They come in various shapes, sizes and colours, making them versatile for different architectural styles. The clay tiles are resistant to extreme weather conditions, insects and fire, adding to their appeal as a roofing material.
Clay Tiles Manufacturing Process
The clay tile making process involves several steps, from extracting raw materials to the final firing and quality checks. Let’s discuss these in detail.
Step 1: Extraction of Raw Materials
The process of making clay roof tiles begins with the extraction of clay from quarries. While the type of clay used might vary, the manufacturers use clay mixed with minerals that give the tiles their strength and colour. They then transport the clay to the manufacturing site, where they store the clay and prepare it for processing.
Step 2: Preparation and Mixing
Once the clay reaches the manufacturing site, the clay mix is prepared. It is first crushed and grinded to remove impurities, which helps in achieving a consistent texture. Then the clay is mixed with water and other additives like sand or grog for enhancing its properties. The mixture is thoroughly blended to ensure its uniformity.
Step 3: Shaping the Tiles
Now the manufacturers shape the clay into tiles using any of two primary methods:
Extrusion: In this method, the manufacturers push the clay mixture through a die to form a continuous strip. They then cut these into individual tiles of the required shape and size.
Moulding: In this method, the manufacturers press the clay mixture into the various shaped moulds to create tiles of specific shapes and patterns. The method allows in creating greater varieties of tiles in design and texture.
Step 4: Drying the Tiles
After shaping the tiles, the manufacturers keep them for drying to remove excess moisture. They perform the action in drying chambers or racks, where the tiles are exposed to controlled temperatures and airflow. However, proper drying is essential to prevent cracks and warps during the firing process. The drying process can take several days, depending on the size and thickness of the tiles.
Step 5: Glazing
Some clay roof tiles undergo a glazing process. During this process, the manufacturers apply a liquid glaze to the tiles’ surface. Besides enhancing the aesthetic appeal by adding colour and sheen, the glaze offers the tiles additional protection against weathering and staining.
Step 6: Firing
Firing forms the crucial step in the clay roof tiles manufacturing process. The manufacturers load the dried tiles into kilns, where the tiles experience high temperatures between 1000 and 1200 degree Celsius. The process hardens the clay, offering the tiles optimum strength and durability. The heat helps fuse the minerals present in the clay, creating a waterproof and weather resistant surface.
Step 7: Cooling and Quality Control
After firing, the manufacturers allow the tiles to cool down slowly. This helps in avoiding thermal shock, which might cause cracking. Once cooled, the tiles undergo a series of quality checks, ensuring that the tiles meet industry standards for strength, colour consistency and dimensional accuracy. The manufactures discard or recycle into new clay batches the tiles that fail to meet the required criteria.
Step 8: Packaging and Distribution
This is the final step, where the manufacturers pack the tiles for distribution. The manufacturers carefully pack the tiles, so that they do not experience damage during transportation. They then ship to the suppliers, contractors or directly to the construction sites.
Why Use Clay Roof Tiles?
Clay roof tiles are popular among the homeowners and construction professionals for their versatility. Enlisted are the key benefits of clay tile roof installation.
Low maintenance
Most roofing materials require frequent repairs and replacement. However, clay tiles are different and demand minimal maintenance. Homeowners can conduct an occasional inspection, replacement and cleaning, which are sufficient to keep them in good shape.
Durability
Clay tiles have the ability to withstand harsh conditions, including heavy winds, hail and even fire. Their robust nature means the tiles can last for decades without any need for replacement.
Energy efficient
Clay tiles are popular for providing excellent insulation. Installing clay tiles in your home keeps your home cooler in summers and warmer in winters. It helps in reducing the heating and cooling costs, making them an energy efficient choice.
Aesthetic appeal
Available in different shapes and styles, these roof tiles complement different architectural styles from traditional to contemporary, thereby enhancing the appearance of your dream home.
Choosing the right Terracotta Roof Tiles for Your Home
Clay roof tiles have emerged as a popular roofing material. With the numerous varieties available, it becomes difficult to choose the right one for your home. Enlisted are top tips homeowners must consider when choosing clay tiles for their homes.
Climate
Certain parts of India experience unpredictable weather, heavy rain and strong winds. Therefore, when choosing your clay roofing tiles, it’s vital to consider the climate of your region. If you live in a region with harsh weather conditions including strong winds, torrential rains and snow, opt for clay tiles that are durable and resistant to these climatic conditions. Choose tiles that have a high wind rating, resistant to water absorption and freeze-thaw cycles.
Style and Colour
Clay roof tiles come in various styles and colours. Therefore, you must choose tiles that complement the architectural style and colour of your home. Opt for tiles that match with or complement the existing colouring scheme of your home to add visual interest to your roof. You can simply opt for the traditional red and brown clay tiles, as they blend well with the natural surroundings, complementing the local architecture.
Maintenance and Repair
Although terracotta roof tiles are durable and long lasting, they might require maintenance and repair over time. Choose tiles that are easy to maintain and repair. Ensure to keep handy the replacement tiles in case of damage or breakage. If you live in a region that receives heavy rainfall, moss and algae growth are common problems. Therefore, you must opt for tiles that are easier to clean.
Conclusion
Clay roof tiles, with a blend of functionality and aesthetic appeal, are a timeless and durable material for your roofs. Understanding the process of manufacturing these tiles will help you appreciate their value. When choosing the roofing tiles for your home, ensure to consider its benefits, types and factors. Besides helping you make an informed decision, it will enhance the beauty and longevity of your home.
As a leading and trustworthy construction company in India, Brick & Bolt offers you the best roofing solutions to meet the highest standards of quality. With the professionals’ focus on using the best materials, the organisation offers exceptional clay tile roofing with optimum durability, thermal insulation and aesthetic appeal. Brick & Bolt ensures that their professionals execute each project with precision, offering long-lasting protection and enhancing the beauty of your homes. Our commitment to superior quality and customer satisfaction has helped us become a reliable choice for property owners seeking premium-roofing solutions in modern construction. Contact Brick & Bolt today to build your dream home!