Ceramic Process
How it's done...
The process begins with many bags of high-fire clay. A typical project can use anywhere from 350lbs. of clay. Bags of clay are emptied onto the slab roller and pressed into a consistent 3/4" slab. Once a slab has been prepared, the sculptured artistic elements are added. These tiles are then cut, to best hide the cutting lines, and its left to dry for as long as one month.
The second step of the process is the glazing. Each tile must be painted with the glaze and checked for any drips that would ruin the firing shelf. Once the glaze is applied and dried, the tiles are ready for firing.
The firing occurs at 2300F where the extreme temperature hardens and vitrifies both the clay and the glaze. It is this firing that makes for such durable, long-lasting works, suitable for both outside and in.
After cooling, the pieces are taken to the job site to be assembled. Before any tiles can be mounted, a wooded jig is erected to support the structure during installation. Then layer, upon layer, the tiles are installed, grouted, and finally cleaned. Installation of a piece can take anywhere from 1-3 days.