Double charge vitrified tiles are manufactured by feeding a double layer of pigments through a press that prints the patterns. The design possibilities of these tiles are limited but got excellent qualities in terms of strength and durability.
Classification of Vitrified tiles
Vitrified tiles are available in a wide range of variations to cater to any functional requirements and costs. They can cater to high traffic areas like airports, metro stations, railway stations, industrial uses to small residential applications. The category and types of vitrified tiles are tailor-made for adapting to any application.
- Soluble salt vitrified tiles
- Glazed vitrified tiles,
- Double charge vitrified tiles
- Full body vitrified tiles
The classification is based on the method of manufacturing, method of vitrification, material qualities, density, type of traffic, colour choices and functions.
Must read : Types of vitrified tiles – Advantages and uses
This article is exclusively about Double charge vitrified tiles and their difference from Glazed Vitrified tiles (GVT) that includes Digitally glazed vitrified tiles (DGVT) and polished glazed vitrified tiles (PGVT) as shown in the figure.
Digitally glazed vitrified tiles (DGVT) are simply Glazed vitrified tiles (GVT) digitally printed whereas Polished Glazed Vitrified tiles (PGVT) are the extra polished version of Glazed Vitrified tiles/ Digital Glazed Vitrified tiles.
Manufacturing method of vitrified tiles
Vitrified tile is made by hydraulic pressing a mixture of clay, quartz, feldspar, and silica. The hydraulic pressed tiles are heated in kilns at a temperature of around 1000-1400 degrees centigrade. The ingredients like Quartz, silica, and feldspar melts and transforms into a glass-like hard layer. This process of manufacturing is called the vitrification process which means making like glass. At high temperatures, the molten silica fills the gaps and air bubbles thereby making the surface extremely strong and non-porous. The manufacturing process is the one that makes vitrified tiles a much superior option to ceramic tiles. The vitrification process makes vitrified tiles dense, non-porous, abrasion-resistant, and durable than ceramic tiles.
Double charge Vitrified tiles
Double charge vitrified tiles are fed through a press that prints the pattern with a double layer of pigment, 3 to 4 mm thicker than other types of tile.
These types of tiles are also called double-loaded tiles and are made from a mixture of clay, quartz, feldspar, and silica. They do not have a glazed layer and hence digital printing is not possible in these tiles. For Double charged vitrified tiles the designs are formed with a double layer of a pigment having a thickness of 3-4 mm thick. That means the upper layer of the design mix is 3-4 mm thick and contributes almost 30% of the total tile thickness. Tiles are passed through a press where they are fed with the design mix and pressed into the tile body. On firing at high temperature the thick pigment layer melts and fuses to become a part of the tile body and not a layer as in Glazed Vitrified tiles. The tile surface is further nano-polished for making it non-porous, extremely durable, and abrasion-resistant with superior qualities.
Why double charge tiles are superior to Glazed Vitrified tiles.
When you are thinking of floor tiles a plethora of options will come. One is the cheapest and colourful option and another one is durability and strength. A digital tile is always a good option in terms of colour choice, durability, and economy.
But what makes Double charge tiles superior to Glazed Vitrified tile?
| Double charge vitrified tiles | Glazed Vitrified tiles(GVT)/Digital Glazed Vitrified tiles(DGVT)/ Polished Glazed Vitrified tiles (PGVT) |
| Double charge tiles are available in matt and glossy finishes. The tiles are nano polished for extra glossiness and are know as Double charge polished vitrified tiles. | Glazed vitrified tile is known as a digital and polished glazed vitrified tile. They are available in Matt and Glossy finishes. |
| Durability | |
| The upper pigment/design layer of Double charge tiles is very thick and constitutes around 30-40% of the total tile thickness. | The upper design layer of Glazed Vitrified tiles is only 1-2 mm thick vitrified layer and constitutes around 1/10th of a tile body. |
| The manufacturing process (Vitrification process) melts and fuses the 3-4 mm thick pigment /design layer into the tile body and transforms it as part of the tile. | The top layer is digitally printed and vitrified to a glass-like layer through the vitrification process. The thickness is around 1-2 mm normally. |
| The vitrification process produces an extremely durable, and wear-resistant and highly impervious surface and constitutes more than 1/3 rd of the tile body. | The vitrified layer is only 1-2 mm thick against 3-4 mm of Double charge tiles and are not so strong and wear-resistant like Double Charge tiles. |
| Double charge vitrified tiles got in a long-wearing tile surface, suitable for heavy traffic and vast commercial projects. | Glazed vitrified tiles got a reasonable wearing surface capable of medium to low traffic and used mostly for residential applications. |
| Hardness | |
| Hardness value in Mohs scale is ranges between 6-8 | Hardness value in Mohs scale is 4 – 6 |
| Scratches are less noticeable due to the high design thickness/pigment layer of 3-4 mm | Scratches formed are visible in GVT tiles due to low glazing thickness. |
| The design will not fade and the original sheen is maintained. | Designs fade in high traffic areas and loose its charm. |
| Designs and colour choice | |
| The colour layer is formed by merging pigment layers spread through the press. Due to technological limitations, design possibilities are limited. | Design possibilities are unlimited. Uses digital printing techniques and can print any type of texture and colours. |
| Stain resistance & Maintenance | |
| Double charge tiles have extremely good stain resistant qualities and are very easy to clean and maintain. | Stain resistant properties are low compared to Double charge vitrified tiles. |
| Areas of applications | |
| Even with the design limitations, the tiles look classy and elegant. Double charge tiles are a combination of beauty and strength. Mostly used in high traffic interiors and also for residential uses where strength and durability are the primary criteria. | GVT tiles are highly aesthetic and can match any designs and colour schemes. Mostly used in residential and low traffic interiors |
| Cost comparison | |
| Even though cost is high the Double charge tiles are premium quality tiles and got excellent performance in terms of durability,strength, hardness, stain resistant,water resistant properties. | They are comparatively affordable tiles, got a huge variety of designs and textures, and are the best choice for residential buildings with medium to low traffic areas. |
Difference between glazed Vitrified and Double charge Vitrified tiles
Conclusion
Double charge vitrified tiles are where beauty meets strength. An increase in costs is compensated by its long-lasting and durable surface and its capability to cater to heavy traffic. Digital Glaze and Polished Glaze Vitrified tiles are cheap, strong, got a huge variety of designs, and can be a part of residential uses with low to medium traffic.