Mastering Imperfect Extruded Porcelain

Keywords: Extruded Porcelain Tile, Tile Installation Finesse, Grout Joint Size, 3/16" Grout, 1-2mm Variation, Larger Trowel, Non-Rectified Edges.

Episode Summary

Extruded porcelain tiles offer exceptional durability, unique textures, and are highly resistant to stains, acids, and frost. However, their wet-formed, high-pressure manufacturing process—likened to the Play-Doh Fun Factory—means that size variations are inherent and expected.

Join us as we reveal the expert techniques needed to install this material successfully, covering why the tiles are often mistakenly labeled "defective" and the crucial role that a wider grout joint and a larger trowel play in achieving a flawless, professional finish. We dive into how embracing the material’s "imperfect perfection" transforms the final look.

Timestamps and Discussion Points

[0:00 ] Introduction: The Quirk of Extrusion

Introducing extruded porcelain tiles, which are shaped by forcing wet clay through a high-pressure die.

The comparison to the Play-Doh Fun Factory to explain the unique manufacturing process.

Addressing the common installation issue where edges pull apart or tiles do not lie flat, leading contractors to claim the material is defective.

[1:30 ] Section 1: Extruded Tile Basics and Durability

Process: Extruded tiles are wet-formed from clay mixtures, sometimes including additives like feldspar or silica. They are fired at very high temperatures (1200–1400°C).

Composition: This results in an ultra-dense, non-porous product with low water absorption (<0.5%).

Strength: Extruded tiles boast high mechanical resistance and offer total resistance to stains, acids, frost, and thermal shock. They are suitable for outdoor and heavy-traffic areas.

Aesthetics: They provide a more textured, natural, or rustic appearance and can be produced in complex shapes and thicknesses ranging from 8–20 mm.

[3:30 ] Section 2: Why Variation is Normal (The 1–2 mm Allowance)

The Tolerance: It is expected that extruded porcelain pieces will vary. A size difference of 1–2 mm is normal and "within norm and allowance".

The Inevitability of Imperfection: "Perfection in this type of product is not possible".

Causes of Variation: The wet clay mixture and subsequent firing process cause less predictable shrinkage compared to dry-pressed tiles. Complex shapes (e.g., Star and Cross patterns) are inherently harder to control dimensionally.

Lot Variations: Using different tile shapes (e.g., a white polished star and a white matte cross) from separate production lots (e.g., 55N and 54NA) could potentially contribute to size differences.

[6:30 ] Section 3: Installation Secrets and Essential Finesse

The Critical Grout Joint: The only way to "remove any difference that the tiles could be" is to use a wider joint. A minimum grout joint of 3–4 mm is required. For marketing purposes, 3/16" is recommended as the standard for most users. Increasing the grout joint helps mitigate issues.

The Trowel Upgrade: Use a larger than normal trowel. This allows for more mortar and the necessary "adjustment in the face" to compensate for tiles that may not lie flat or are bowed.

The Expert Approach: Installing extruded tiles "definitely takes some finesse". Skilled installers often avoid spacers, as adjustments to joints are "inevitable". Experts set tiles and adjust the fit manually as they work.

[10:30 ] Conclusion: The Final Transformation

A quick recap that what looks like a problem when dry-laid is solved by proper technique.

The product "after install in the correct way and grout change the look completely," delivering the desired look.

Key Takeaways for Installers and DIYers

Acknowledge Variation: Recognize that 1–2 mm size differences are normal for extruded porcelain.

Go Wide: Always use a minimum grout joint of 3–4 mm (or 3/16") to absorb inherent variations.

Adjust: Use a larger than normal trowel to provide the mortar volume needed for essential adjustments and leveling.

Embrace Finesse: Skilled installation requires dynamic adjustment rather than rigid reliance on spacers.