BURNT CLAY TILE ROOFING

INTRODUCTION
CLAY ROOF TILES ARE THE MOST ADMIRE ROOFING MATERIAL. CLAYS ARE DISTINGUISHED FROM OTHER FINE-GRAINED SOILS BY DIFFERENCES IN SIZE AND MINERALOGY. IT SHOULD BE REMEMBERED THAT THE RAFTER PITCH IS ALWAYS STEEPER THAN THE TILE PITCH. CLAY TILES ARE HEAVY, REQUIRING A STRONG SUBSTRUCTURE AND CLOSELY SPACED BATTENS. THEREFORE, TILE DESIGN EX.MANGLORE TILE WHICH REQUIRE WIDER SPACING OF BATTENS, ARE LIGHTER AND MORE ECONOMICAL.

WHAT IS MEANT BY CLAY?

IT IS A STIFF STICKY EARTH, USED FOR MAKING TILES,POTTERY. IT OCCURS PLENTY IN NATURE. IT IS DISTINCT PRODUCT OF CHEMICAL WEATHERING OF IGENEOUS ROCKS. WHEN CLAY MADE WITH WATER, POSSESES A HIGH DEGREE OF TENACITY & PLASTICITY. THE CLAY CONTAINS WATER IN TWO FORMS 1)FREE WATER (REMOVED DURING DRYING) 2)COMBINED WATER (REMOVED CHEMICAL)

CONSTRUCTION TECHNIQUE
HOW TO PREAPARE BURNT CLAY TILE?
FOLLOWING FOUR DISTINCT OPERATION ARE INVOLED IN GENRAL PURPOSE: 1)PREPARATION OF CLAY
WEATHERING

MIXING
GRINDING PUGGING

2)MOULDING 3)DRYING 4)BURNING

PREPARATION OF CLAY
THE SELECTED CLAY IS TAKEN AND IT IS MADE FREE FROM ANY IMPURITIES,SUCH AS GRITS,PEBBLES ETC.

AFTER THAT IT CONVERTED FINE POWDER IN PUG MILLS.

A LARGE QUANTITY OF PURE WATER IS ADDED TO THE POWERED CLAY.

IT IS WELL MIXED IN A TANK AFTER THAT MIX IT SAND QUITELY.

THE CORSE OF HEAVY PARTICLES SETTEL AT THE BOTTOM OF TANK.

THE FINE PARTICLES ARE TAKEN INTO OTHER TANKS AND THE WATER IS THEN ALLOWED TO DRY OFF.

NOW IT CAN USED FOR MANUFACTURED OF BURNT CLAY TILES

WEATHERING
THE SOIL LEFT IN HEAPS AND EXPOSED TO ATLEAST THREE MONTHS. IT DEVELOPES HOMOGENEITY IN THE MASS OF CLAY. IF THERE BE ANY INSOLUBLE SALTS IN THE CLAY THIS WOULD BE WASHED OFF BY RAIN TO A GREATER EXTENT.

MIXING
THE MATERIAL SHOULD BE MIXED IN PROPORATION.

GRINDING
THE CLAY MIXED IN THE PROPER PROPORTION SHALL THEN BE PASSED THROUGH A HIGH SPEED GRINDING ROLLERS.

PUGGING
THE PROCESS OF GRINDING CLAY WITH WATER AND MAKING IT PLASTIC IS KNOWN AS PUGGING. TO ACHIEVE BETTER QUALITY PRODUCTION AND BETTER FINISH WITH REGARD TO APPEARANCE, THE EXTRUSION OF THE SLAB SHALL BE CARRIED THROUGH A DEARING PUG MILL.

MOULDING
THE CLAY IS PLACED IN MOULDS WHICH REPRESENT PATTERN OR SHAPES IN WHICH THE TILE IS TO BE FORMED. IT IS DONE EITHER IN WOODEN MOULDS OR MECHANICAL OR POTTERS WHEEL. THE METHODE OF MOULDING BY POTTERS IS SIMILAR TO MANUFACTURE OF EARTHENWARE.
WOODEN MOULDS

POTTERS WHEEL

DRYING
THE TILES AS THEY COME OUT OF MOULDS, ARE PLACED IN FLAT ONE ABOVE OTHER IN SUITABLE NUMBER.THE DIFFERENT HEAPS ARE FORMED. THEY ARE STACKED ON EDGES AND UNDER A SHADE TO DRY FOR ABOUT 2 DAYS OR SO.

THE DRYING UNDER A SHADE PREVENTS WARPING AND CRCKING OF TILES DUE TO RAIN AND SUN.

BURNING
IT IS CIRCULAR IN SHAPE AND PROTECTED BY SHED. THE TOP OF KILN IS COVERED WITH A LAYER OF OLD TILES PLACED IN A LOOSE CONDITION.

A TYPICAL KILN ,KNOWN AS SIALKOTE KILN,FOR ACCOMODATING ABOUT 30000 TO 40000 TILES.
THE REGULATION OF HEAT.

APPLICATION OF BURNT CLAY TILE

Special properties Economical aspects Stability Skills required Equipment required Durable, waterproof cladding for sloped roofs Low to medium costs Good Skilled labor Clay tile production unit, roof construction equipment Low

Resistance to earthquake Resistance to hurricane Medium to good Resistance to rain Very good Resistance to insects Very good Climatic suitability All climates, but most common in humid areas Stage of experience Traditional

USES
IT IS USED FOR SLOOPING ROOF. IT IS USED FOR 20 and 50 INCLINATION
OF RAFTER AND THE TILE SHAPES DIFFER FOR EACH RANGE OF SLOPE.

ADVANTAGES
CLAY TILES ARE LESS LIABLE TO DIAPLACEMENT BY BIRDS. THESE TILES MAY BE USED AS A SOLE COVERING TO THE ROOF. THE PITCHED ROOF MAY BE MADE COMPLETELY LEAK PROOF.

TYPES OF ROOF TILES