TILE PRESSING CLAYSreduce production costs through greater flexibility
Optimum performance for modern tile manufacturingThe Premiere™ range of plastic clays (ball clays) are carefully selected, engineered mineral products designed to give optimumperformance in tile pressing applications.Sibelco Ukrainian Premiere tile pressing clays have been engineered using mineralogically unique feed clays which are blended tohave excellent plasticity and strength. They possess an exceptionally unique illitic mineralogy which combines very high dry strength,plasticity and high vitrification together with stable shrinkage at low firing temperatures.These low carbon clays are ideal components to control thermal expansion, dimensional accuracy and fired colour in high quality tileapplicationsKey Features of the Ukraine Premiere range include:• exceptionally high strength & plasticity• low colouring oxides• low carbon• high fusibility with controlled vitrification & shrinkageThey are ideally suited as the sole clay in a formulation or can be used to improve the performance of local clays.Recommended Applications Recommended Tile Applications Glazed Unglazed Product Wall Floor Porcellanto Porcellanto DBY – 4 DBK – 0 DBK – 1 DBK – 2E The Ukraine Premiere range is especially suited for making large format, super thin tiles due to their exceptional plasticity whichsupports improved mechanical resistance and high dimensional accuracy.Premiere products can benefit customer production processes by improving pressing and firing characteristics of porcelain tile due to:• low colouring oxides = white firing colour• unique mineralogy = high plastic unfired strength & production yield• high alkali content = low fired porosity & improved frost resistance• consistency in quality variations = high first grade tile production & minimized size variation for end customer products Chemical and Analytical Data – typical values which do not represent aspecification Property unit DBY – 4 DBK – 0 DBK – 1 DBK – 2E SiO2 Mass % 60.0 61.0 62.0 66.0 Al2O3 Mass % 26.0 25.0 24.0 21.0 Fe2O3 Mass % 1.0 1.1 1.2 0.9 TiO2 Mass % 1.6 1.6 1.7 1.7 K2O Mass % 2.6 2.4 2.3 2.5 Loss on Ignition % 7.2 7.1 6.8 6.0 Modulus of Rupture (dried 110°C) Mpa 9.0 8.5 8.5 8.0 Residue > 125µm % greater 4.5 4.8 4.8 5.0 Particle size @ 2µm % finer 75 75 75 75
The Ukraine Premiere range of products offers significant advantages over locally available tile pressing clays. Their unique mineralogy and pressing characteristics can improve plasticity and breakage resistance: Figure 1: Plot of modulus of rupture against strain to illustrate the difference in overall unfired strength improvement in a standard vitreous porcelain body against local plastic clays 20 18 Body Standard 16 14 Body 12 3% Figure 2: Calculated body “toughness” Premiere-2MOR/Kg cm 10 Toughness 8 Body /kg cm-2 5% 6 Premiere Body Standard 0.000651 4 Body 3% Premiere 0.001191 2 Body 10% 0 Premiere Body 5% Premiere 0.001149 0 0.002 0.004 0.006 0.008 0.01 0.012 0.014 0.016 Body 10% Premiere 0.001254 Strain (%) Premiere products have high vitrification yet stable linear shrinkage, optimising firing cycle times and providing greater dimensional accuracy. Figure 3: Vitrification properties: water absorption & linear shrinkage contraction % Water absorption % o o Temperature C Temperature C When fired to the same temperature, there is no significant change in visual properties (L*a*b*) between the trial body formulations. However, if we compare the whiteness at similar water absorption, by plotting % water absorption against L, then significant improvements in whiteness can be seen by using Premiere products, especially at low water absorption values. Figure 4: Plot of L* against % water absorption Whiteness (L) Water absorption % Trial data is based on comparisons of Premiere DBK-0 to local clay used in a large format pressed vitreous stoneware tile formulation. Utilising feldspar @ 55%, Kaolin @ 5%, Silica @ 8%, Talc @ 2% and local plastic clay @ 30%.
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