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Clay Roofing Tiles - REHDA | Institute

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Getting it Right 3-

Clay Roofing Tiles by:

Mr. Julien Chnebierk FMM Malaysian Ceramic Industry Group (MCIG) 13 October 2016 REHDA Institute

Presentation Outline  Manufacturing Process Flow of Clay Roof Tiles  Why Clay Roofing Tiles ?

 Comparison Between Clay Roofing Tiles vs. Concrete Roof Tiles, Metal Roofing & Asphalt shingles  Type of Clay Roof Tiles and Finishes

 Installation Guidelines and Usage of Roofing Components  Clay Roof Tiles Technical Specification & Warranty  Roof Care & Maintenance

 Q&A

Clay Roofing Tiles Recipe

Earth +

Water

+

Fire =

Clay Roofing That Lasts Centuries

Clay Roofing Tiles MANUFACTURING process

Clay Material Preparation Extraction of Clay from the Quarry and transported to factory to storage as stockpiles in the plant

Clay Roofing Tiles MANUFACTURING process Grinding & Screening the Clay At the start of manufacturing process, clay is collected from the stockpile and loaded into the feed hoppers

Water, sand & additives are added to the clay and mixed in accordance with the recipe Clay mixture is then fed into the clay preparation where it is ground and homogenized

Clay Roofing Tiles MANUFACTURING process Extrude and Tile Forming

The prepared clay mix pass through an extruder to produce slabs of clay

Mechanical PRESS It then loaded on a moulder press & form the precise format

Clay Roofing Tiles MANUFACTURING process Drying Process Pressed clay roof tiles will then send for drying. Depending on drying method used, it may take 1 – 3 days for the process. Moisture removed in dryer

Colour Pigment Then, using disk cabins for engobing the tiles before firing

Clay Roofing Tiles MANUFACTURING process FIRING clay tiles It then transfer to firing kiln & may takes 48 – 72 hours depending on type of kiln

It usually fired by natural gas and achieve a maximum temperature of > 1000°C Tiles travel through the various heating stages and cooling on a kiln car which moving on a rails

During firing, clay roof tiles achieved strength and durability by the high temperature mineralogical process

Clay Roofing Tiles MANUFACTURING process Packaging and Storage

After UNLOAD the products from kiln cars by ROBOT, roof tiles are inspected for the quality

Strapping machines to PACK the tiles on pallets and placed in storage area and delivery

Clay Roofing Tiles MANUFACTURING process Ready for Delivery forklifts to LOAD the pallets on trucks or in containers and ready for delivery

Presentation Outline  Manufacturing Process Flow of Clay Roof Tiles

 Why Clay Roofing Tiles ?  Comparison Between Clay Roofing Tiles vs. Concrete Roof Tiles, Metal Roofing & Asphalt shingles

 Type of Clay Roof Tiles and Finishes  Installation Guidelines and Usage of Roofing Components  Clay Roof Tiles Technical Specification & Warranty  Roof Care & Maintenance

 Q&A

Why Clay Roofing tiles? Because it is Beautiful

…!

Clay Roof Tiles : Exclusive beauty. Clay Roofs unveil the beauty of the earth, and offers endless customization possibilities

Why Clay Roofing tiles? Clay Roofing Tile is Green

Made of earth ! No harmful or endangered raw materials 100% NATURAL !

Why Clay Roofing tiles?

Long lasting aesthetic to your roof !

Color will never fade and will be permanent !

Clay Roof Tiles : Latest Technology for High Performance Roof Computerized moulds & Pressing technology for best-in-class performance and consistence in dimension accuracy, water-tightness, strength and security, as well as perfect finishes

Clay Roof Tiles : Product strength,

Packaging quality

Truck loading and container stuffing expertise result into no breakage on land / sea transport

Clay Roof Tiles : Durable. Engobed clay roof tiles basically can last for decades, with no hidden maintenance costs. Other materials, often painted, will deteriorate much faster and incur heavy maintenance. Clay Roof Tiles after 25 & 35 years

Others Roofing materials after 15 years

Why Clay Roofing tiles?

Clay roof provides good thermal insulation & better comfort. 3°C cooler compared to Concrete roof Cooler home environment for better comfort Reduce the need of air – conditioning

Save energy, save money for long term

Clay Roof Tiles : Energy efficiency. A modern and Environment-friendly product, with ever-lasting cooling properties enhancing your Comfort of Living

Clay Roof Tiles : Energy efficiency. A modern and Environment-friendly product, with ever-lasting cooling properties enhancing your Comfort of Living

Concrete Roof Tiles 29.4°C

Clay Roof Tiles 25.6°C

Clay Tiles + Insulator 23.8°C

Clay Roof Tiles : Energy efficiency. Best-in-class Solar Reflectance Index (SRI) performance, in particular with White Glazed finished tiles

Clay Roof Tiles : Cost efficiency. Technology improvements enabled to produce larger formats, fast and easy to install, that will enable significant savings on materials and installation costs Technology of mass production

Computerized moulds

Pressing technology

Customization

Can produce Large formats & Any color

Affordable

Less tiles needed by M2

Save materials cost

Maintenance free

Lower installation costs

Why Clay Roofing tiles?

Clay roof tile is exclusive & stylish It enhances the value of the property It is the Secret to beautiful Homes !!!

Presentation Outline  Manufacturing Process Flow of Clay Roof Tiles  Why Clay Roofing Tiles ?

 Comparison Between Clay Roofing Tiles vs. Concrete Roof Tiles, Metal Roofing & Asphalt shingles  Type of Clay Roof Tiles and Finishes  Installation Guidelines and Usage of Roofing Components  Clay Roof Tiles Technical Specification & Warranty

 Roof Care & Maintenance  Q&A

Difference Between Clay Roof Tiles Vs. Concrete Roof Tiles 1 Clay Roofing Tiles

Concrete Roofing Tiles

Materials

Made from Earth, 100% natural Product !

Made of Cement & sand !

Process

Pressed, Dried and Fired at > 1000°C

Extruded. Dry by natural air

Color Permanence

Color embedded, Permanent & long lasting

Paint Coated on surface, Color tone down over years

Heat Resistance (Energy Saving)

Excellent Heat Insulator

Average Heat Insulator.

Product Life Cycle

Durable & can last more than 50 years to century

Life Span 20 to 30 years. Reroofing Often required after this period

Difference Between Clay Roof Tiles Vs. Concrete Roof Tiles 2 Clay Roofing Tiles

Concrete Roofing Tiles

Fungus Growth

Glazed & Semi Glazed finished – almost no fungus Natural finished – common but washable

Common with moss / algae but not advisable to wash due to product characteristic (Porous)

Roof Profile Features

Double Interlocking & Double Overlapping System (DIDO) for Excellent water tightness

Overlapping system only

Home Value / Aesthetic

It looks exclusive and prestige

Common and not stylish, More for affordable home because of cheaper cost

Product Warranty

10 Years International Warranty

No Warranty

Difference Between Clay Roof Tiles Vs. Metal Roof Tiles Clay Roofing Tiles

Metal Deck

Materials

Made from Earth, 100% natural Product !

Made of Metal

Process

Pressed, Dried and Fired at > 1000°C

Extruded / Casted

Color Permanence

Color embedded, Permanent & long lasting

Paint Coated on surface, Color tone down over years & depends on surface coating

Energy Saving

Excellent Heat Insulator

Poor Heat Insulator

Product Life Cycle

Durable & can last more than 50 years to century

It will be long if not rusted

Fungus Growth

Glazed & Semi Glazed finished – almost no fungus Natural finished – common but washable

No

Roof Profile Features

Double Interlocking & Double Overlapping System (DIDO) for Excellent water tightness

No overlapping. Join / clip-lock system.

Home Value

It looks exclusive and prestige

Looks common, commercial and not stylish

Product Warranty

10 Years International Warranty

Back to back Warranty from metal coil supplier & surface coating

Difference Between Clay Roof Tiles Vs. Shingles Roof Tiles 1 Clay Roofing Tiles

Shingles

Materials

Made from Earth, 100% natural Product !

Petroleum based product, not a environmental friendly roofing materials

Color Permanence

Color embedded, Permanent & long lasting

Extreme heat can cause shingles loose color

Resistance to heat

Excellent Heat Insulator

Poor Heat Insulator. Shingles absorb heat from sun and transfer it into house

Product Life Cycle

Durable & can last more than 50 years to century

Last 30 years. Surface will deteriorated after years of expose to hot weather

Difference Between Clay Roof Tiles Vs. Shingles Roof Tiles Clay Roofing Tiles

Shingles

Fungus Growth

Glazed & Semi Glazed finished – almost no fungus Natural finished – common but washable

yes . For rainy season with excess moisture, shingles start to rot

Roof Profile Features

Double Interlocking & Double Overlapping System (DIDO) for Excellent water tightness

Overlapping each tiles with 3040% of surface

Home Value

Exclusive and prestige. Enhance the property value

It looks vintage. Widely use in Northern America because of inexpensive cost

Product Performance

DIDO system provide water tightness and difficult to lift up

Strong wind can uplift or tear shingles off easily.

Product Durability

Durable and long lasting against severe temperature

Not resistant to extreme hot weather. Expansions & contraction of the shingles can cause cracking

Presentation Outline  Manufacturing Process Flow of Clay Roof Tiles  Why Clay Roofing Tiles ?  Comparison Between Clay Roofing Tiles vs. Concrete Roof Tiles, Metal Roofing & Asphalt shingles

 Type of Clay Roof Tiles and Finishes  Installation Guidelines and Usage of Roofing Components  Clay Roof Tiles Technical Specification & Warranty  Roof Care & Maintenance

 Q&A

Family of Clay Roofing Tiles Available In Malaysia

COLOUR / FINISHES : Glaze, Satin (Semi Glazed), Tropical Tones & Natural

GLAZED

SATIN / SEMI GLAZED

TROPICAL TONE

NATURAL TONE

Presentation Outline  Manufacturing Process Flow of Clay Roof Tiles  Why Clay Roofing Tiles ?  Comparison Between Clay Roofing Tiles vs. Concrete Roof Tiles, Metal Roofing & Asphalt shingles

 Type of Clay Roof Tiles and Finishes

 Installation Guidelines and Usage of Roofing Components  Clay Roof Tiles Technical Specification & Warranty  Roof Care & Maintenance

 Q&A

Clay Roof Tile: Provide Full range of accessories for Installation

• Complete roofing fitting tiles to cover main potential areas of leakage  Ridge  Hip and Valley  Flashing  Socket Lantern

Roofing Components Is required To Minimize the Leakage Issues

Dry Fix Dry Flash

Reflective Insulation

DRY FIX method for Ridge / Hip / Mono pitch Roof …

Vs

Dry Fixing Membrane for Ridge / Hip Application

Dry Fixing Membrane • Durable • Fast and easy installation • Adheres strongly on all material • Can be painted to match tile •Self sealing if punctured

Mortar • Very messy and ugly • Will crack after weathering and caused leakage

DRY FLASHING MATERIALS and Flash Strip … Dry Flash is a perfect solution for wall abutment, providing better and neat finishing : • Highly durable - Full aluminium product • Easy and fast installation

• UV resistance colour coating • Butyl adhesive strips- additional security against rain

Vs

DRY FLASH AT ABUTMENT & PARTY WALL

ZINC FLASHING AT ABUTMENT

Clay Roof Tiles : Technical Expert to support installation & training Flashing details

Eaves details

03.Champagne PARIS BLUE SIERRA RED (G.1) (MS.1)

BORDEAUX MAROON (G.2) DRAKKAR BROWN (MS.2)

11.Sahara Beige

Overlapping details

EIFFEL COGNAC BROWNPEACH (MS.3) (G.3)

13.Storm Grey

Dry Fixing details 15.Slate Grey

BERLIN GREEN (G.4)

GRAPHITE O MANGO BLACK (G.5) (MS.5)

PLATINUM MILAN GREY LEATHER (MS.6) (G.6)

Presentation Outline  Manufacturing Process Flow of Clay Roof Tiles  Why Clay Roofing Tiles ?  Comparison Between Clay Roofing Tiles vs. Concrete Roof Tiles, Metal Roofing & Asphalt shingles

 Type of Clay Roof Tiles and Finishes  Installation Guidelines and Usage of Roofing Components

 Clay Roof Tiles Technical Specification & Warranty  Roof Care & Maintenance

 Q&A

Clay Roofing Tiles are compliant to • SS 70:2001 Singapore Standard – Clay Roofing Tiles and Fitting • Most of Clay Roof Tiles suppliers are ISO9001:2008 certified • Most Manufacturers have obtained CE marking on their Products for export market

Clay Roofing Tiles: Provide a 10-year warranty on their products

Others Related Roofing Components, reflective Insulation are compliant to • •

MS 1525:2014 Malaysia Standard – Energy Efficiency and Use of Renewable Energy MS 2095:2014 Malaysia Standard – Radiant Barrier and Reflective Insulation Building Material

Presentation Outline  Manufacturing Process Flow of Clay Roof Tiles  Why Clay Roofing Tiles ?

 Comparison Between Clay Roofing Tiles vs. Concrete Roof Tiles, Metal Roofing & Asphalt shingles  Type of Clay Roof Tiles and Finishes

 Installation Guidelines and Usage of Roofing Components  Clay Roof Tiles Technical Specification & Warranty

 Roof Care & Maintenance  Q&A

ROOF CARE AND MAINTENANCE Clay Roof Tiles are amongst the most durable roof covering available and should provide many years of satisfaction. Under normal conditions of use, only minimum care and maintenance required, which is normally the responsibility of the owner

Recommendations for roof care: - Control growth of fungus and algae - Keep free of debris, fallen leaves - Ensure all valleys, gutters, pipes are in clear and good order - Check condition of chimney stacks, flashing - Special precautions must be taken to avoid damage to the roof tiles

Curative Treatment for Fungus On Natural Finishing

Biocide treatments. A very efficient biocide is bleach (a 12% chlorine solution is very efficient). The bleach can effectively clean away fungus without much effort.

Water Repellent Treatment. This is very effective for natural finished clay roof tiles. Normally water based silicon is used for this purpose. This silicon treatment will seal up the pore of the tiles and provide water repellent properties. The solution has only timelimited effects since the product gets progressively washed away by the rain. It can take one or two years before fungus re-appear.

TIME TO GO GREEN… Save the planet & save money !

Clay Roofing Tiles

Reflective Insulation

+

Q&A

FAQ

Q : What is the differences between glazed and satin? A : Glazed is more shinning and glossy than satin & both have the anti-fungus properties. Q : How long can the natural tones stand before fungus starts growing? A : Normally it depends on the situation of the house and humidity level. If there are a lots of tree surrounding the roof which provide a lot of shelters and shade, the fungus can growth faster compared to an open area. The roof pitch and drainage of the roof are also 2 key factors. The steeper the roof the less fungus growth, as the running of water is faster.

FAQ

Q : What is your minimum pitch? A : Depend on the area of the house : whether it is a protected area (in a valley for example), a normal area or an open area (near a beach for example) or exposed to strong wind. You can go as low as 19 degree if underlaying material is used. The span of the roof is also a factor, the longer the span the higher the pitch needs to be. Q : Is it necessary to use complete range of accessories & roofing components? A : Yes. Complete range of accessories is tailored to each potential leaking area of the roof. Roofing Components is necessary for long lasting roof performance and less maintenance.

FAQ

Q : Can clay roof tiles be installed on a steel batten? A : Yes. The steel batten has to be 90º at the hooking side and the tiles are fixed by self tapered screw. Q : Can you tailor made for special colour? A : Yes. Custom color is possible but it always conditioned with a minimum quantity (MOQ) and cost will depends on pigment used. Q : What is the recommended roof pitch? A : In normal circumstance, the recommended roof pitch is 25 to 35 degrees. However, it subject to roof profile, roof span, exposure to wind and rain of the roof & use or not under laying. Roof pitch between 25 degrees to 35 degrees will optimise the flow of water and waterproofness of the roof. Furthermore, it allows to visualise the profile from ground level.

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Clay Roofing Tiles - REHDA | Institute

Getting it Right 3- Clay Roofing Tiles by: Mr. Julien Chnebierk FMM Malaysian Ceramic Industry Group (MCIG) 13 October 2016 REHDA Institute Presen...

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