CERAMIC

Group members
• NAME:
1. Lee Jian Ru 0318132
2. Darren Loong Chi Yoong 0318029
3. Chong Kai Xiang 0322935
4. Kiing Kiu Chun 0318727
5. Hiew Li Ming 0319941
6. Hong Kai Yin 0323361
7. Chee Wei Shan 0319572
8. Michelle Lee Ern Hui 0319703
9. Lily Then 0313973
10. Lau Chin Sheng 0317899
11. Willliam Goh Ming Hann 0317949
History of Ceramics
-Ceramics that date back to at least 24,000 BC. Flourished
in Upper Egypt about 8,000 BC.

- In the Middle Ages, when the metal industry was in its

infancy. The industrial revolution was born, when synthetic
materials with better resistance to high temperatures
(called refractories) were developed in the 16th century.
These refractories created the necessary conditions for
melting metals and glass on an industrial scale, as well as
for the manufacture of coke, cement, chemicals, and
ceramics.
History of Ceramics (CONT’)
• -Another major development occurred in the second half
of the 19th century, when ceramic materials for electrical
insulation were developed. As other inventions came on
the scene-including automobiles, radios, televisions,
computers-ceramic and glass materials were needed to
help these become a reality, as shown in the following
timeline.
Ceramics: Composition of Clay

-main compositions are feldspar group of minerals

comprise around 60% of the earth's crust. They are
aluminium silicates, also incorporating alkali and/or alkaline
earth metals.
Ceramics: Composition of Clay(CONT’)
-Clays are divided to two types:
1) Primary clay:
-usually found in the same place as the feldspar from which
it originated
-is relatively rare and has particular properties with which
potters must work.(pure materials)
-earthen clay (the kind from the ground, which is often
glazed/sealed and "fired" in a kiln with very high heat after
air-drying)(less plastic)
-absorbs more water compared to the secondary type of
clay.
Ceramics: Composition of
Clay(CONT’)
2) Secondary clay:
-have been transported by wind, water or both from their
places of formation.

-are far more abundant and tend to be easier to form and

fire.
-Polymer clay is oil-based (not water-based and "air-dry"
like most other "clays") so it has no water to lose and can't
"dry" out and is pretty impervious to water.(Higher
plasticity)
- is pretty impervious to water.
- absorbed water and/or drying won't hurt the clay though
or make it less strong.
Manufacturing Process of
Ceramics
Types of Moulding
• Injection moulding
- Optimal process for manufacturing large series of relatively
small components. By mixing ceramic powder and suitable
binder systems it is possible to injection mould ceramic
components. The polymer binder is burned off in a separate
burn off stage before sintering.
Types of Moulding (cont’)
Types of Moulding (cont’)
• Isostatic pressing

- Ceramic powder is fed into a

moulding bag inside an isostatic
press.

- The press is sealed and the

isostatic pressure is increased.
Types of Moulding (cont’)

- The powder compacts and

forms a solid in the form of the
moulding bag. The pressure is
released and the press can be
open to remove the formed
ceramic component.
Characteristics
• Bending Resistance

• High Hardness

• High degree resistance to moisture

• Resistance to impact and abrasion

• Excellent resistance to chemical attack

Characteristics (cont’)
• Temperature up to 2400 °C

• Can be design to various type of pattern

• Can be painted to various type of colors

• Roofing tiles contains more than 30% water which have

considerable drying contraction

• Wall and floor tiles contain 2-5% water have greater

accuracy in shape and size
Characteristics (cont’)
• All floor tiles can be used on walls and others surface but
not all wall tiles can be used on floors

• Installed in Portland cement setting bed or special epoxy

adhesives

• Rarely accurate in shape and size

• Most advanced ceramic materials are combination of

ceramics and others materials known as Ceramic Matrix
Composites
Advantages of Ceramic
• Durable
• -extremely hard.
• -last 10-20 years and longer.
• -handle extremes of heat and cold very well.
• Easy to clean
• -stain resistant.
• -hygienic, not absorb liquids, does not retain the residues and
smells of chemicals, foods or beverages.
• -simply vacuum and use damp mop.
• Design options
• -modern manufacturing techniques allow ceramic producers to
make materials which can be printed in numerous ways.
Advantages of Ceramic (cont’)
• Cost
-relatively inexpensive, cheaper than hard wood, carpet.
- Once you absorb the initial cost of tile you don’t have to
spend money on it again for the life of the product if it is
installed properly.
• Can be installed in nearly any application
-on floors, walls, in showers, backsplashes, ceilings
-countertops, table tops, fireplaces, columns and more
-water resistance, can be installed in wet environment.
• High scratch resistance
• Resistance to burns
Advantages of Ceramic (cont’)
• Resistance to fading
-not fade due to sunlight and electrical light.

• Environmental friendly
-100% natural materials.
Disadvantages of Ceramic
• Temperature
-Ceramic is cold when used as flooring and can be quite
uncomfortable during cold climate.
-density of ceramic.
-during hot climate, warm ceramic tile takes a long time
to cool.
• Ceramic installation
-intensive installation, hard and heavy and they need to
be
installed using a variety of mortars, grouts, and tools.
-higher labor cost.
Disadvantages of Ceramic
• Ceramic Tile Weight
-Ceramics are quite heavy, which means that they may not
always be appropriate for upper story installations.

• Hard Flooring
-difficult and uncomfortable to stand on.
-Unlike resilient floors, hard tile ceramics cannot be softened
using padded underlayments.
-not suitable at environments where people will be forced
to stand for long periods of time.
Properties of Ceramics
• Ceramics are best known as brittle solids particularly
suited for withstanding high temperatures but, in fact, the
different materials used in ceramics can gives them a
wide range of properties.

• The classic properties of ceramics include durability,

strength and brittleness, high electrical and thermal
resistance, and an ability to withstand the damaging
effects of acids, oxygen, and other chemicals because of
their chemical unreactive.
Properties of Ceramics (cont’)
• But not all ceramics behave in this way. For example,
graphite is a very soft ceramic and conducts electricity
well, whereas diamond is a very good good conductor of
heat.

• Ceramics called ferrites are particularly good conductors

of electricity and superconductors have almost no
electrical resistance at all.
General properties of ceramics
• Hard
• Wear – resistant
• Brittle
• Refractory
• Thermal insulators
• Electrical insulators
• Nonmagnetic
• Oxidation resistant
• Prone to thermal shock
• Chemically stable
Daily Uses of Ceramics
• Bowls and plates
• Accessories or ornament for clothing
• Housing : floor tiles, bricks, roof tiles and so much more
TYPES OF CERAMIC
1. Terracotta
2. Stoneware
3. Fireclay
4. Earthware
5. Roofing
6. Porcelain
7. Vitreous China
TYPES OF CERAMIC
• 1. Terracotta

•This is a type of earthenware, is a clay-based unglazed or

glazed ceramic, where the fired body is porous.

•Uses include flower pots, water and waste water pipes,

bricks, and surface embellishment in building construction.

•Natural, brownish orange colour.

TYPES OF CERAMIC
1. Terracotta
• Faience : a glazed form of terracotta or stoneware
• Fired to the biscuit condition and then glazed before
refiring
• Alternatively, unfired faience may be glazed and ‘once
fired’
• Once fired : a process which improves resistance to
crazing of the glaze while reducing the range of colour
• When water can penetrate, crystallization of salts and
frost action will cause failure, thus faience with low water
absorption is preferable as it is resistant to frost.
TYPES OF CERAMIC
• 1. Terracotta
Uses of Terracotta :
• Easy to clean
• Crazing of inferior products collect grime
• Suitable for in–ground use to carry
pressurized water
• Garden ware
• Oil containers
• Ovens
• Building decorations in tropical environments
or in freezing environment ( need to be glazed
)
 TYPES OF CERAMIC
• 1. Terracotta
Disadvantages of Terracotta :

• Expensive : it is rather costly when compared to the other

tiles useful for construction reasons.

• Sensitive : fragility, not suitable to receive heavy knocks

• Loss of colour : within the passage of time, these types of

tiles often fade and lose its original deep colour
TYPES OF CERAMIC
2. STONEWARE
1. Stoneware is a vitreous (glass) or semi-
vitreous ceramic made primarily from stoneware clay or
non-refractory fire clay.

2. Stoneware is fired at high temperatures and it is

nonporous.
 TYPES OF CERAMIC
• 1. STONEWARE
Composition :
Stoneware is made up of 3 major component, which is clays, fluxes and fillers.

Clay:
- The basic clays found in stoneware clay body formulas are high-
temperature refractory clays. Each group of clays provides specific attributes to the
total clay body formula, including fired strength, shrinkage and plasticity.

Fillers:
- Fillers reduce clay body shrinkage and warping in the drying and firing
stages. If the amount of filler is too high, the clay body's plastic qualities will be
decreased.
TYPES OF CERAMIC
1. STONEWARE
Composition :
• Fluxes:
Fluxes help lower the melting point of heat-
resistant clays and fillers and increase the glass
formation in a clay body. Using the wrong flux or
an incorrect amount can have disastrous
consequences.
TYPES OF CERAMIC
• 1. STONEWARE
FUNCTION :
• Artware
• Chemical ware
• Cookware
• Drainpipe
• Kitchenware
• Tableware
• Tile
TYPES OF CERAMIC
Manufacturing process
1. STONEWARE of stoneware pipes
TYPES OF CERAMIC
2. Fireclay

1. Fireclay is a type of clay that is able to withstand

intense heat.

2. It is suitable for making articles which will not melt, nor

even perceptibly soften when exposed to a high
temperature.
TYPES OF CERAMIC
• 2. Fireclay
Composition :

Fireclay consists alumina and silica.

Alumina:
It is also named alumminium oxide. It has high thermal conductivity and good
electrical insulator which makes it suitable for making ceramics.

Silica:
It is also named silicon dioxide. It is a major constituent of sand. It has high
thermal stability and is a good electrical insulator, same as alumina.
TYPES OF CERAMIC
• 2. Fireclay
FUNCTION :

• Sink
• Bathtub
• Tiles
• Crucible
• Firebricks
TYPES OF CERAMIC
• 2. Fireclay
Manufacture process of fireclay
 TYPES OF CERAMIC
3. Earthenware
• Earthenware is also called low fired clay because it is normally matured
at low temperature
• Finer than stoneware
• Porosity, high water absorbtion of 5-8%
• Must be glazed to prevent water absorbtion
• small cracks in glaze is permeable to water
• Less suitable for sanitary ware compared to vitreous china
• Not translucent and are more easily to chipped, less strong than
stoneware
• There are two main types of glazed earthenware:
1 ) creamware 2) tin-glazed
TYPES OF CERAMIC
• Roofing

• Low water absorbtion

• High slip resistant
• This allows rainwater to flow downwards without leaking between tiles
• Durable chemical and frost resistance
• protects you from water during the rain, heat in summer and cold in winter
• last for about 400 years without losing its beauty and effectiveness
• Come in traditional red, brown or antique which are unglazed with a plain
finish
 TYPES OF CERAMIC
• Porcelain

• A special type of clay either white or grey, to which kaolin (a

white firing stiff clay) and white China stone (finely decayed
granite, washed and prepared as small white blocks) is
added.

• Primary components - clays, feldspar or flint and silica

 TYPES OF CERAMIC
• Porcelain
Manufacture process of Procelain :

1. Crushed using jaw crushers, hammer mills, and ball mills.

2. Cleaning to remove improperly sized materials
3. The mixture is subjected to one of four forming process —soft plastic
forming, stiff plastic forming, pressing, or casting—depending on the type of
ware being produced.
4. The ware then undergoes a preliminary firing step, bisque-firing.
 TYPES OF CERAMIC
• Vitreous China

• Mixture of clay, feldspar and quartz which is molded, glazed

and "baked" at extremely high temperatures
• material which is strong, nonporous and impervious to
absorption.
TYPES OF CERAMIC
• Vitreous China
The word “vitreous” means “glass-like,”
glaze makes ordinary ceramics look shiny and
reflective while maintaining & strengthening their
durability.
The glaze itself is usually made of composite minerals
and powdered glass.
1. It is typically sold as a powder that artisans and manufacturers must
melt down, in a kiln or specialized oven, before using.
2. Once the glaze has reached its melting point it can be painted, or
“glazed,” onto the surface of the ceramic piece.
3. The enamel must usually be left to dry for a time, then the piece re-
fired to seal the coating.
4. Past this point, the item can usually be itself described as “vitreous
china.”
TYPES OF CERAMIC
• Vitreous China
• Similarities :

• Substances formed by firing clay and other

minerals at high temperature

• Have extremely low porosity

• Can be glazed and unglazed

TYPES OF CERAMIC
Vitreous China
Differences :

Porcelain Vitreous china

is fired, 1,454 degrees is fired, 1,204 degrees
Celsius Celsius

Has great hardness known as soft-paste or

tender porcelain, is softer
translucent opaque
TYPES OF PRODUCTION
• 3 Types of ceramic based on production processes:
a) Glazed
b) Mosaic
c) Quarry
TYPES OF PRODUCTION
• GLAZED TILES

• used for interior and exterior

• produced in modular size with matching trim piece for
comers, wall bases and nosing
• heavier coat glazing for floor tiles than wall tiles
TYPES OF PRODUCTION
• GLAZED TILES
ADVANTAGES OF GLAZED TILES FOR FLOORING :
• extremely strong
• easy to clean and maintain being stain free, acid and alkali resistant
• has a very high abrasion resistant
• does not attract dust
• bacteria free
• good insulators
• fire proof
• easy to lay and ready for live in use in a matter of 48 hours after laying
• available in many shades
• anti slip unlike white glaze tiles ceramic floor tiles are salt and are slip
and non skid
TYPES OF PRODUCTION
• GLAZED TILES
DISADVANTAGES OF GLAZED TILES FOR FLOORING :
• high cost
TYPES OF PRODUCTION
• GLAZED TILES
ADVANTAGES OF GLAZED TILES FOR ROOFING :

• create distinctive style on home or building

• fire safety
• non-combustible
• maintain color permanence
• durability
• unique resistance to the elements of Nature
TYPES OF PRODUCTION
• GLAZED TILES
DISADVANTAGES OF GLAZED TILES FOR ROOFING :
• unsuitability for climates with fluctuating weather
• prone to erosion under these conditions
• while the tiles are durable, they are also fragile
• can be damage by high wind
TYPES OF PRODUCTION
• MOSAIC TILES

Mosaic is the art of creating images with an assemblage of

small pieces of coloured glass, stone, or other materials. It is a
technique of decorative art or interior decoration. Most mosaics
are made of small, flat, roughly square, pieces of stone or glass
of different colours, known as tesserae; but some, especially
floor mosaics, may also be made of small rounded pieces of
stone, and called "pebble mosaics".
TYPES OF PRODUCTION
• MOSAIC TILES

CHARACTERISTICS :
• Used for exterior and interior.
• Produced in modular size with matching piece for corners, wall
bases and nosing.
• Heavier coat glazing for floor tiles than wall tiles.
• Made in small sizes for composing intricate patterns for use in mural
on floors and walls.
• Smoother, brighter and more impervious than glazed tiles.
• Glazed or unglazed.
 TYPES OF PRODUCTION
• MOSAIC TILES

ADVANTAGES :
• Hard wearing
• Frost proof
• Resistant to chemical
• Unglazed mosaic used for wet area eg: swimming pools
• Good slip resistance
TYPES OF PRODUCTION
• MOSAIC TILES

Unglazed Mosaic tiles for

Mosaic tiles mural
swimming pools
TYPES OF PRODUCTION
• Quarry

-Made of shales and fine clays.

- A type of unglazed tile.
-The bottom side of a quarry tile is ridged to encourage adhesion to
grout.
-The top of the tile has a coarse surface because it is not glazed .
- This surface encourages traction, which can be very useful in
environments like pathways and kitchens.
TYPES OF PRODUCTION
Quarry tiles

Indoor Outdoor
TYPES OF PRODUCTION
• Quarry tiles
outdoor

Garden Step-tiled
TYPES OF PRODUCTION
• Quarry tiles
Indoor

Kitchen Toilet
 Quarry tiles

Quarry Tile

Advantages Disadvantages
1)Slip –resisting 1) easy being
2)Inexpensive stained
(does not require glaze) (no glaze,
3)Durable liquid
penetrates
easily)
2) mold and
fungus occurs