Structural clay tile describes a category of burned-clay building materials used to construct roofing, walls, and flooring for structural and non-structural purposes, especially in fireproofing applications. Also called building tile, structural terra cotta, hollow tile, saltillo tile , and clay block, the material is an extruded clay shape with substantial depth that allows it to be laid in the same manner as other clay or concrete masonry. In North America it was chiefly used during the late 19th and early 20th centuries, reaching peak popularity at the turn of the century and declining around the 1950s. Structural clay tile grew in popularity in the end of the nineteenth-century because it could be constructed faster, was lighter, and required simpler flat falsework than earlier brick vaulting construction. [1]
Each unit is generally made of clay or terra-cotta with hollow cavities, or cells, inside it. The colors of terracotta transform from gray (raw, moist clay) to orange, red, yellow, and cream tones. This is due to an effect of the firing process which hardens the clay so it can be used for structural purposes. [2] The material is commonly used in floor arches, fireproofing, partition walls, and furring. [3] It continues to be used in Europe to build fire-resistant walls and partitions. In North America the material has largely been replaced by concrete masonry units.
Clay tile in different capacities has been used for thousands of years. The Romans were among the first to use clay tile in construction by building clay pots to lighten vaulting loads. [4] However the first recorded structural use of terra-cotta forms was in sixth-century Italy in the dome of the Church of San Vitale in Ravenna. Clay pots lined with plaster of paris lightened the load of the dome in a similar way to earlier Roman construction. [3]
The first recorded use of structural clay tile in the United States was in 1853. Frederick A. Peterson designed hand-shaped clay ovals that he placed between I-beams and covered with cement to create flooring. Peterson debuted his method in the Cooper Union Building in New York City. However, Peterson's method was not mass-produced or replicated until the 1870s. [4] In 1871, Balthasar Kreischer and George H. Johnson patented a new method similar to Peterson's, based on earlier precedents including those of British architect Joseph Bunnett in 1858, as well as designs by Peterson. [4] Each of these methods emerged out of a growing need to fireproof buildings following massive fires across the United States during that last quarter of the nineteenth century.
Before the widespread use structural clay tile, brick and masonry construction dominated fireproofing techniques. However, brick and masonry construction, especially vaulting, was heavy, time-consuming to construct, and required the construction of costly custom formwork. [4] Structural clay tile offered a lighter, faster, and simpler alternative. An interlocking system of angular clay tiles that were fit together with a keystone became popular in the early 1870s after designs by Vincent Garcin were mass-produced to create flat segmented arches. [4] This flat segmented arch, developed by Garcin, was first used in the United States at the New York Post Office, Kendall Building in Chicago, and the Singer Manufacturing Building in St. Louis, becoming the most prolific use of hollow clay tile until the end of the century. [4]
With its increased popularity, structural clay tile became one of the most popular materials for fireproofing iron and steel construction. [4] However, its capacity for fireproofing was not fully realized until Peter Bonnett Wight invented the "tile shoe" in 1881. The "tile shoe" covered the exposed side of metal beams, fully insulating them from fire. [1]
Flat arch construction grew in popularity with the increasing number of buildings using steel and iron structural members in their design. New building code requirements for fireproofing aided in the use and proliferation of structural clay tile in skyscrapers and other large buildings. [3] After 1910, manufacturers began to test and develop stronger and more complex structural clay tile systems that worked better in compression. Greater compressive strength, found largely in the invention of the end pressure arch, allowed the material to be used in longer floor spans. [3] However, as reinforced concrete grew in popularity as a cheaper and less complex alternative, structural clay tile use in floors and roofing declined. Increasingly, clay tile was used inside concrete flooring to make it lighter, or as centering/formwork for concrete construction. [4] [3]
With the rise of reinforced concrete flooring and metal decking, structural clay tile fell out of popularity for use in horizontal applications. [3] While the use of structural clay tile in flooring and roofing declined, its use in walls enjoyed popularity into the 1950s. [4] Wall tile blocks continue to be manufactured, but specialty tile units often require custom commissions. [3] Clay tile arches are no longer manufactured and due to a lack of skilled artisans to lay the arch systems, they are never replaced. [3]
Side pressure arch construction, the first method used in tile floor arches, is composed of hollow tiles laid parallel to I beams. [4]
End pressure arch construction is composed of hollow tiles laid perpendicular to I beams. This method enjoyed popularity after it was discovered to be fifty percent more efficient than side pressure arches. [3] [4]
A popular use of structural clay tile was book tile, a flat hollow tile, that was used in roofing systems. Book tile was also used in raised flooring to allow plumbing and other systems to be run in buildings. [4]
In the late 1890s, the most popular system of tile floor arches combined both side and end pressure construction. However, with the increase in popularity of concrete construction, composite construction began to use both methods in conjunction with reinforced concrete. Later systems used clay tiles and reinforced concrete to replace tile floor arches in the 1930s. [3]
The most popular and enduring form of structural clay tile is its use in vertical applications as a structural element. In the vertical application, structural clay tile blocks are used in both columns and load bearing walls. Likewise, structural clay tile blocks were frequently used as backing for exterior walls, often filling the voids behind architectural ornament, stone, or brickwork. [3] In early steel construction, clay tile blocks were historically used as infill between structural members, which provided much needed lateral support. [3] In some cases, entire walls—typically in single-story buildings, seldom higher—were created out of structural clay tile, typically multiple wythes thick. [3] The cells of these blocks could be either unfilled or filled with reinforcing and grout. [3]
Structural glazed facing tile is perhaps its most common and prolific form of clay tile block. Structural glazed facing tile has been extensively used in institutional settings where a durable, easily cleanable surface is desired. The material is commonly found in schools, correctional facilities, swimming pools and similar facilities. A wide variety of shapes have been developed to allow the construction of corners, caps, wall base and other elements using standard sizes. SGFT cannot be easily cut without damage to the glazed surface, so several dozen special shapes are available to allow most situations to be accommodated. SGFT features a fired glazed surface that may be produced in colors similar to those available from standard ceramic tile. [5] SGFT has been replaced in some applications by glazed masonry units, a composite of concrete masonry and a tile-like surface coating.
Specialized kinds of structural clay tile were produced with a vitrified or glazed curved surface for use in building farm silos. Other shapes, called "telephone tiles", were used as underground multi-celled conduits for telephone cables. [6]
Structural clay tile is still manufactured according to historical processes: clay is kneaded to an appropriate consistency, pressed into molds. and fired in large kilns. [3] Different molds and forms are used for each type and shape of structural clay tile.
Structural clay tile is classified into three grades: hard, semi-porous, and porous. Each classification is differentiated by the length of time the tile is fired during the manufacturing process, and each classification is used for different purposes. [3]
Hard tile has the greatest structural strength of the three categories, and is used largely in applications where it is exposed to the elements. Its hardness resists moisture, as it is less porous than other classifications. However, hard tile is less fireproof as it is prone to cracking in high heat. [3]
Semi-porous tile has moderate strength and is resistant to moisture.
Porous tile is made by mixing clay with straw, sawdust or other materials that are burned out during the manufacturing process making it highly porous and lighter, in addition to reducing structural dead loads. Porous tile was preferred among builders for fireproofing since it behaved well in high heat. [3]
Tile is classified into load-bearing and non-load-bearing categories. Load-bearing tile is described under ASTM Standard C34, subdivided into grade LBX, for areas exposed to weathering, and LB, for protected applications. Non-load-bearing tile is described under ASTM C56 in one grade, NB. It is used for interior partitions, and may be laid with cells running horizontally or vertically. Tile may be ribbed to accept a plaster finish, or smooth. Special shapes were available to attach to and to fit around structural steel shapes, providing a fire-resistant enclosure for the load-bearing steel members. [5] [7]
Structural clay tiles are manufactured in a variety of standard sizes, including 4 inches (10 cm), 6 inches (15 cm), 8 inches (20 cm), 10 inches (25 cm) and 12 inches (30 cm)thicknesses, and typically 12 inches (30 cm) x 12 inches (30 cm) or 12 inches (30 cm) x 8 inches (20 cm) face dimensions. [5] Tile was also manufactured in a series of graduated wedge shapes for installation between steel members as a fireproof flat arch floor structure, to be covered with a concrete wearing surface above. In other cases, structural clay tile was used as a permanent form material to reduce the bulk and weight of structural concrete floor slabs. [8]
A brick is a type of construction material used to build walls, pavements and other elements in masonry construction. Properly, the term brick denotes a unit primarily composed of clay, but is now also used informally to denote units made of other materials or other chemically cured construction blocks. Bricks can be joined using mortar, adhesives or by interlocking. Bricks are usually produced at brickworks in numerous classes, types, materials, and sizes which vary with region, and are produced in bulk quantities.
Masonry is the craft of building a structure with brick, stone, or similar material, including mortar plastering which are often laid in, bound and pasted together by mortar. The term masonry can also refer to the building units themselves.
A floor is the bottom surface of a room or vehicle. Floors vary from simple dirt in a cave to many layered surfaces made with modern technology. Floors may be stone, wood, bamboo, metal or any other material that can support the expected load.
Terracotta, also known as terra cotta or terra-cotta, is a term used in some contexts for earthenware. It is a clay-based non-vitreous ceramic, fired at relatively low temperatures.
Flooring is the general term for a permanent covering of a floor, or for the work of installing such a floor covering. Floor covering is a term to generically describe any finish material applied over a floor structure to provide a walking surface. Both terms are used interchangeably but floor covering refers more to loose-laid materials.
Stonemasonry or stonecraft is the creation of buildings, structures, and sculpture using stone as the primary material. Stonemasonry is the craft of shaping and arranging stones, often together with mortar and even the ancient lime mortar, to wall or cover formed structures.
Tiles are usually thin, square or rectangular coverings manufactured from hard-wearing material such as ceramic, stone, metal, baked clay, or even glass. They are generally fixed in place in an array to cover roofs, floors, walls, edges, or other objects such as tabletops. Alternatively, tile can sometimes refer to similar units made from lightweight materials such as perlite, wood, and mineral wool, typically used for wall and ceiling applications. In another sense, a tile is a construction tile or similar object, such as rectangular counters used in playing games. The word is derived from the French word tuile, which is, in turn, from the Latin word tegula, meaning a roof tile composed of fired clay.
Building material is material used for construction. Many naturally occurring substances, such as clay, rocks, sand, wood, and even twigs and leaves, have been used to construct buildings and other structures, like bridges. Apart from naturally occurring materials, many man-made products are in use, some more and some less synthetic. The manufacturing of building materials is an established industry in many countries and the use of these materials is typically segmented into specific specialty trades, such as carpentry, insulation, plumbing, and roofing work. They provide the make-up of habitats and structures including homes.
Glass brick, also known as glass block, is an architectural element made from glass. The appearance of glass blocks can vary in color, size, texture and form. Glass bricks provide visual obscuration while admitting light. The modern glass block was developed from pre-existing prism lighting principles in the early 1900s to provide natural light in manufacturing plants. Today glass blocks are used in walls, skylights, and sidewalk lights.
A concrete block, also known as a cinder block in North American English, breeze block in British English, concrete masonry unit (CMU), or by various other terms, is a standard-size rectangular block used in building construction. The use of blockwork allows structures to be built in the traditional masonry style with layers of staggered blocks.
This page is a list of construction topics.
Natural building is the construction of buildings using systems and materials that emphasize sustainability. This in turn implies durability and the use of minimally processed, plentiful or renewable resources, as well as those that, while recycled or salvaged, produce healthy living environments and maintain indoor air quality. Natural building tends to rely on human labor, more than technology. As Michael G. Smith observes, it depends on "local ecology, geology and climate; on the character of the particular building site, and on the needs and personalities of the builders and users."
The Guastavino tile arch system is a version of Catalan vault introduced to the United States in 1885 by Spanish architect and builder Rafael Guastavino (1842–1908). It was patented in the United States by Guastavino in 1892.
Steel frame is a building technique with a "skeleton frame" of vertical steel columns and horizontal I-beams, constructed in a rectangular grid to support the floors, roof and walls of a building which are all attached to the frame. The development of this technique made the construction of the skyscraper possible.
Glazed architectural terra cotta is a ceramic masonry building material used as a decorative skin. It featured widely in the 'terracotta revival' from the 1880s until the 1930s. It was used in the UK, United States, Canada and Australia and is still one of the most common building materials found in U.S. urban environments. It is the glazed version of architectural terracotta; the material in both its glazed and unglazed versions is sturdy and relatively inexpensive, and can be molded into richly ornamented detail. Glazed terra-cotta played a significant role in architectural styles such as the Chicago School and Beaux-Arts architecture.
Autoclaved aerated concrete (AAC) is a lightweight, precast, cellular concrete building material, eco-friendly, suitable for producing concrete-like blocks. It is composed of quartz sand, calcined gypsum, lime, portland cement, water and aluminium powder. AAC products are cured under heat and pressure in an autoclave. Developed in the mid-1920s, AAC provides insulation, fire, and mold-resistance. Forms include blocks, wall panels, floor and roof panels, cladding (façade) panels and lintels. It is also an insulator.
Fireproofing is rendering something resistant to fire, or incombustible; or material for use in making anything fire-proof. It is a passive fire protection measure. "Fireproof" or "fireproofing" can be used as a noun, verb or adjective; it may be hyphenated ("fire-proof").
Architectural terracotta refers to a fired mixture of clay and water that can be used in a non-structural, semi-structural, or structural capacity on the exterior or interior of a building. Terracotta pottery, as earthenware is called when not used for vessels, is an ancient building material that translates from Latin as "baked earth". Some architectural terracotta is actually stronger than stoneware. It can be unglazed, painted, slip glazed, or glazed.
Gedung Kuning is a Malay historical residence in Singapore. Located at 73 Sultan Gate, Gedung Kuning stands just outside the Malay Heritage Centre, near Masjid Sultan in the historic district of Kampong Glam in Singapore. However, from 1919 to 1925, the Gedung Kuning's address was 33 Sultan Gate. Once forming an annexe to the adjacent palace of Singapore's Malay rulers, Istana Kampong Glam, it became the private residence of Haji Yusoff, a prominent Malayo-Javanese merchant and four generations of his family. Together with the Istana, the compound was refurbished as part of the development of the Malay Heritage Centre in 2004.
Ceramic building material, often abbreviated to CBM, is an umbrella term used in archaeology to cover all building materials made from baked clay. It is particularly, but not exclusively, used in relation to Roman building materials.
{{cite book}}
: CS1 maint: location missing publisher (link) CS1 maint: others (link)