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Introduction to Cement Tiles
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Cement tiles, also called Portuguese tiles or pattern tiles, are handmade tiles based on cement and pigments. Are you looking for a tile that can brighten up your home or garden? The Portuguese tile is suitable for indoors and outdoors, for floors and walls. Does the Portuguese tile fit in your home?
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These tiles are mainly known from the stately homes of the 1920s, but the colorful patterns also fit into other interior styles such as the country, bohemian or Scandinavian style. Are you looking for a tile that will brighten up your bathroom, hall, toilet or kitchen? Then the Portuguese tile is perfect.
History of the Cement Tiles
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Cement, pigment, water, time and patience: these are the ingredients that make a decorated cement tile, just as the Moors did ten centuries ago. Although the production techniques have been refined over the years, the artisanal and environmentally friendly handicraft remains central. The Europeans learned the art of making colorful cement tiles from the Moors, who poured colored marble powder into a mold, sprinkled cement over it and pressed it together into a sturdy tile for floors and walls. The Moors brought these techniques to Spain when they conquered the country in 711, and their influence can still be seen in cities such as Cordoba, Seville and Granada, with the Alhambra Palace as the pinnacle of Moorish Arabic architecture. The walls of this building are beautifully decorated with countless multicolored tiles. Although cement tiles fell out of fashion after the Moors were expelled in 1492, they were rediscovered in the nineteenth century by archaeologists who rekindled interest in Arabic designs full of geometry, calligraphy and flowers. Today, cement tiles are popular again, both in historical and modern architecture. New designers in the Mediterranean have adopted the basics of these designs and adapted them to their own cultural tastes, leading to a renewed appreciation for this unique form of craftsmanship.
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Art Nouveau: At the end of the nineteenth century, cement tiles were particularly popular with Barcelona's high society, with Antonio Gaudí as an important designer within the Art Nouveau movement. Gaudí designed an apple-green hexagonal tile for Casa Milà, and cement tiles became increasingly popular in Spain and southern Europe during this period.
Twentieth century: In the early twentieth century, cement tiles were the most popular floor covering in the Mediterranean region, including North Africa, France, Spain, Portugal, and Italy. They spread to former European colonies and worldwide. This heyday ended in the 1950s, when cheaper industrial materials such as granite, ceramics, and plastics became popular.
Twenty-first century: At the beginning of the twenty-first century, the demand for authentic and sustainable products, such as cement tiles, is growing. This is seen as a response to the technological age, in which industrial materials often cause environmental damage. Cement tiles are produced without heating using environmentally friendly ingredients, and more and more designers appreciate them for their quality and decorative value.
Production of the Cement Tile
A good cement tile is compact, waterproof and very durable. Only the best natural materials such as real marble and pebble powder & organic pigments are used during the production process. These materials are then pressed together by machine under high pressure. The different patterns in this pattern tile are formed by manually inserting the different colours one by one into a handmade copper mould. The tiles are made individually and entirely by hand. It is a very careful and artisanal process that can only be carried out by very well-trained professionals.
The final quality of the tile is determined by its maker. Cement tiles are made up of two different layers that can easily be seen when looking at the tile from the side.
1. For each new pattern, a new copper mold is made by hand. This pattern tile fits exactly into a frame, which in turn is in a hydraulic press. The frame determines not only the size, but also the quality of the top layer of the cement tile. The pigment is poured into the mold color by color, exactly according to the desired pattern. The pigment consists mainly of marble powder, fine white cement, organic pigments and other minerals.
2. After the mold has been removed in a special way, the color layer (first visible layer) is sprinkled with a mixture of very fine sand and cement. This ensures that the excess moisture is well absorbed.
3. The third step in the process is to precisely fill the frame with a thicker mix of sand and cement that is carefully smoothed out. The frame is then completely sealed and the tile is pressed together in the hydraulic press.
4. After the pressing process, the frame and sealer are removed and the tile is carefully inspected for the desired quality and pattern. The tiles are then placed in a water bath for 24 hours to harden. Finally, the tiles are stored in drying racks for another 7 days for final hardening.
Origin and quality
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Our cement tiles, also called pattern tiles, originally come from Morocco, where we started in 2006. Later we discovered that cement tiles were also made in Vietnam, with a superior quality that is much better than those from Morocco. Vietnamese tiles have a smoother and more even surface and are stronger, which has to do with the high-quality raw materials, often imported from Germany, and the pressing techniques. Vietnam, once a French colony, used to get tile presses from France for production.
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After the communist transition, factories had to compete, which led to further perfection of techniques and exceptional quality. We decided to source our cement tiles exclusively from Vietnam; the production costs are comparable to those from Morocco, but the quality is considerably better. The only disadvantage is that Vietnam is further away, which sometimes makes delivery times longer.
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Factories
Over the years we have worked with several factories in Vietnam, which has resulted in slight colour variations in the tiles. To solve this, we entered into discussions with the largest factory, which has both the capacity and the expertise to meet our requirements. We have made clear agreements on delivery times and quality, supported by an ISO certificate. This has resulted in a streamlined production with virtually no colour variations, and deliveries usually arrive in the Netherlands on time, with a few exceptions. We visit our factory in Vietnam regularly. It is a real pleasure to be in Vietnam! The employees work in a clean, well-ventilated environment, and the management ensures excellent working conditions. They have lunch together and benefit from a collective health insurance fund, to which we also contribute. The employees are cheerful and have a positive attitude towards their work. They can work in peace, without the noise and pressure that often prevail in Europe, which allows them to make our beautiful Azule pattern tiles with passion. Child labour is absolutely not an issue; In Vietnam, much is being done to provide children with a good future. Moreover, it takes years to acquire the skills needed to make cement tiles!
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Raw materials
A cement tile is composed of three main components: cement, pigment (marble powder) and water. The pigments used in this process are of organic origin and are pressed under high pressure. The production process is cold. This means that no heat treatment is required, which makes the process not only energy efficient, but also ecologically sound. The water needed to harden the tiles is recycled. A water purification plant is located outside the factory that purifies the water used on site, thus keeping water waste to a minimum. Also, no material is wasted; damaged tiles are donated to local schools for mosaic projects or used as rubble for paving. Tiles with colour differences or production errors are also sent to the local market, where they are donated to schools, orphanages and public places. The entire production process, as well as the raw materials and working conditions used, is sustainable and socially responsible—something we at Designtegels.nl BV fully support and support wherever possible. After seeing the production process, you will understand why these artistically handmade tiles are worth their price. After all, each tile is individually handmade, which is unique.