If you have been contacting roofing companies in Dallas, then you may have considered clay tiles. Before you have the tiles installed, it might be beneficial to understand how they are made.
This is actually a very interesting process that begins with mining for clay. Not just any clay can be used for roofing tiles. It must be the right mixture to ensure resilience against Mother Nature’s elements. Generally, this means that manufacturers mix clays found in different regions to develop a particular strong and worthwhile combination.
The clay is stored at the manufacturer’s warehouses in large pits and some companies will soak it while it waits to be used. In doing so, they can keep the clay wet and pliable for a long period of time ensuring that they can meet growing demands for the roofing material. However, eventually, the clay must be dried to begin the actual manufacturing process. Once hardened, it is fed through grinders to be broken down into a fine, consistent powder. This will remove any large granules that would otherwise cause defects in the tiles. Even at this stage, however, it is not done being manipulated; it is not at the best possible state. The powder is watered down again and fed through a fine screen press to further ensure it’s at the desired texture for roofing tiles. The multiple-stage process delivers the very best possible raw material.
Once the clay has been ‘developed’, it is treated like dough, rolled out into a thick slab in a rolling mill. This system pushes the large clumps of clay through a pair of rollers that squeeze and form it into the slab. This melds it into a long, singular form that is easier to work with. While every manufacturer has a slightly different set-up, the remainder of the process is essentially the same.
The first step of forming it requires the extruder, which forms it into a long, continuous ridged shape. Sharp, motor operated blades then cut the tiles to the desired length. The individual tiles are then punched between two forms that bend them as desired, giving them the traditional arch. From there, they are fed onto trays and placed into a drying chamber.
The drying process will take place over several days, after which color can be added. Random spray patterns are used when treating the tiles with color, which provides a natural, aged look. Some are sprayed with high gloss glazes, while others will maintain their natural matte finish. Again, they are set aside in chambers to dry.
The drying does not take as long the second time around and afterward the clay tiles are ready for the kiln where they are “cooked” at closely monitored temperatures, sometimes exceeding two thousand degrees Fahrenheit. The temperature will depend on the type of tile, the type of pigment added, and the manufacturer. Upon leaving the kiln, the tiles are meticulously studied for notable defects. Testing is rigorous, as the tiles will undergo a great deal of stress and strain once installed on a roof.
Many homeowners in and around Garland, TX recognize the beauty and advantages of clay tiles. Are you tired of dealing with metal roof repair? In Plano, TX, it is easy to find a qualified contractor ready to help you make the switch to clay.
Affordable Dallas Roofing Solutions
3102 Maple Ave #400-A1
Dallas, Texas 75201