Clay Roof Tile

Clay is a natural occurring product and has different colors, shades and variances once it is processed. There’s a wire range between white, yellow, orange and brown clays. But the most commonly used clay is the terra-cotta or “orangy” clay. In roof tiles, the natural color of clay used is this one, and depending on the quality and characteristics of the clay, the manufacturing process and the firing method, the color and final effect may vary a lot!

But in clay roof tiles there’s also another alternative, which is adding enamels to the tile to make any color of roof tiles. This process is called “ceramic” and consists in spraying the enamel to the tile before cook. Then, once the color is applied, it goes to the kiln at very high temperatures and the color bonds to the clay, making them one. This color will not peel off nor fade, thanks to this process. It is a great option to get a high quality roof tile, in the color you choose.

There are many factors that affect the life expectancy of a roof (weather conditions, structure age and condition, natural acts, the material used, installation, maintenance, etc)

In the case of roofing tiles, manufacturers usually claim to have a life expectancy of 50 years or more. Some even guarantee their products for 75 years. This does not mean that roof tiles made out of clay for example, can last even longer. Just a look at the old Europe buildings can give you a true testament of how long and well can clay roof tile last. If the structure permits it and the weather conditions are not so harsh, they can last for centuries.

Moreover, clay roof tiles maintain their color and aesthetic look for its lifespan almost intact (depending on some conditions of quality and weather, too) It is a relatively light weight product and if the structure is new or in good shape, roofing tiles can really extend the life of your property, too.

 The National Association of Home Builders developed a report with information on life expectancy of different products for a home, based on information of manufacturers. The following chart is for roofing products:

With this in mind, it makes complete sense to choose quality products that are guaranteed for more than 50 years. That gives a good idea on the low cost of the total investment.

There are several manufacturers of clay roof tiles in the US and also from all over the word. the following is a list of the most known in the US (national and imported). Please forgive me if I’m missing anyone, and feel free to suggest any other clay roof tile manufacturer that is not listed here so we can all learn.

• - US Tile: their plant is based in California.
• - Ludowici: based in Ohio, this manufacturer claims to be in the clay roof tile business since 1888.
• - MCA: this company is based in California.
• - Gladding McBean: manufactures clay roof tiles and clay floor tiles.
• - RedLand: manufacturers of clay roof tiles
• Santafe Tile: their plants are in Colombia and have their stocking yard in Medley, Fl.
• Altusa: from Venezuela, imported through their office in Miami, FL
• Tejas Borja: from Spain.
• Artesanos: handmade clay roof tiles.

 Quality and characteristics of their products may vary. It is always a good choice to request samples, visit jobsites where the tiles have been installed and ask for references.

One interesting aspect of clay roof tiles is their versatility. Being able to manufacture them in several shapes, colors and textures really provides the user with unlimited looks, styles and roof creations.

Flat roof tiles have been used for centuries, thanks to this versatility, weight, durability and aesthetics. Depending on the desired finished look, today’s clay roof tile market offers a nice variety of flat roof tiles:

•  Soft & Smooth surface: this roof tile has a very soft and even surface, and depending on the color chosen, the final effect may look more like a slate (especially if they are in the grey, dark colors). The final job looks impeccable. This style is booming right now, and is a good match for contemporary constructions.
• Textured surfaces: these tiles are sometimes “brushed” during the manufacturing process, or are done in a mold to simulate a wood texture. The idea is to look like a cedar shingle or wood shingle, but with the durability of a clay roof tile!
• Rounded edges and uniform shapes: these tiles are used depending the areas and are more of an “antique” look. Mostly used in historic buildings or houses.

Flat tiles are a great product for any roof, but specially for roofs with a pitch of 4:12 and up, to really appreciate the effect that they can offer to a project.

One of the most popular models of roofing tiles over the last decade has been this profile: Spanish S. But, why has this become the top seller, especially for clay roof tile manufacturers?

Appearance: the Spanish S tile looks like its original version: the Mission Barrel tile. It simulates being a barrel tile, which is a 2 piece tile, but using only one tile.

Easy installation: thanks to its shape (a barrel and a flat section of approx 3 inches) its installation is much easier than with Mission Barrel. The tiles can fit better and is less probable to make mistakes or install it crooked. If separation between tiles are followed, the job can be done faster and smoother.

Affordable: Since with Spanish S you’ll need less pieces per square (sometimes almost 50% less!) this profile is more affordable and provides a style  pretty close to what the old-world look of mission tiles gives.

Colors, flashing and blends can also be done on Spanish S, the same way they are done with mission tiles. It would be also a matter of the “mastery” of the installer to give a more antique, Mediterranean or contemporary roof tile style with the materials chosen.

As always, this is an aesthetic product and therefore it depends on the personal opinion and search of style of the customer. Both are beautiful, excellent products to beautify any roof. It will depend on the style and particular design perception that is intended to express on an specific project.

There are many reasons why a roof tile can have or develop stains in different shapes, levels and colors. The most common reasons are inherent to the nature of the product. Concrete roof tiles are more porous than clay, therefore they tend to develop mold more easily, creating black stains that grow each year and even though they can be cleaned the porosity of these tiles make it even easier each time for the development of this undesirable agent.

But there are other factors and effects that roof tiles can be subject to:

Mold, Algae and other natural agents: Once installed, roof tiles can be victims of some organisms that “feed” from some components of the roof tiles (either concrete or clay, and its components). These organisms attach to the roof tiles with much strength that are not easy to be cleaned normally. They even tend to grow with time if the weather conditions help them to grow. There are some trees that tend to have these agents and provide great conditions for them to develop on the roof. If we add humidity, porosity of the roof tiles, the trees and the components of the tile, these organisms find a new home in your roof!

Stains can be in black or green, depending their nature and weathering conditions. To eliminate them, first try to pressure clean your roof. If still they do not come off, then it is needed to take a lab exam of the organisms attached to the tiles. Just with a small piece of the tile, a lab can tell you exactly what is that is growing in your tiles. Once you know if its mold, algae or anything else, you’ll be able to look for the appropriate solution.

There are a few chemical companies that can provide products to clean the roof tiles. But the most important thing is to determine what has caused the mold or algae to develop, because if the problem is not solved from the root, it will come up again and again…

Perhaps one smart approach would be to contact the manufacturer of the roof tiles and ask if they have knowledge of this problem happened before and if so, there is a solution they know of…

Since clay is a natural product, color variation may occur depending on different factors. Some clays have different tones and that has its beauty… Some firing processes may burn the clay in different ways, making the natural clay color vary from darker to lighter, and that adds a natural flashing to the tile.

But there are other clay roof tiles that are pretty consistent with their colors thanks to a very controlled process from the mining to the firing. Gas kilns give stable temperature throughout the firing process, which helps to avoid noticeable color differences on the roof tiles.

Some people like to have variations of colors to create a natural, earthy-looking roof. In this case, the only problem is that since the variances can not be controlled, there may be difficult to get the same color over time. And even in the same pallets of the order, it would be hard to tell if the blending would be “natural” or acceptable in design or style terms.

Manufacturers of clay roof tiles that are consistent with their colors would even guarantee that there will not be visible color variation over 30 or 40 ft distance. In these cases, if you want to do a blend, then you can choose different colors and create unique blends.

Clay is a natural product and it is natural that there will be tone differences, especially from one production to another. But the level of color variation needed will depend on the project and desired effect.

Depending on the region you live on, the need of a roofing contractor may be mandatroym by law! In Florida, for example, the permits and the job has to be perfomred by a certified roofing contractor. In other States, this is not mandatory and the job will depend on the experience of general contractor, builder, remodeler, installer, etc.

When we talk about roof tiles, some contractors get scared. But there’s no reason for it, is just a matter of learning some basic skills for the installation and how to walk on tiles to avoid brekages. Not all contractors are open to this learning process, and prefer to stick to the “old” line of products they are used to. In this case, it is always the best to ask for references of roof tile installations, see what products they know, how long have they been in business and what do they think of the product you want to install. Don’t let the unexperienced contractor to tell you all negative things about roofing tiles! Some common un-based information an unexperienced contractor will tell you about roof tiles are: roof tiles break easily (if they are properly installed and they know how to walk on them, there’s no reason for breakage); they are the worst for hail areas (when a hail storm strikes, almost any roof product will be damaged);  they are too heavy! (this may be true for concrete roof tiles and you may need additional estructural support, but clay roof tiles are much lighter and usually the extra support is not needed); it’s too expensive! (if you compare the life expectancy of a roof tiled and a shingle, the difference is paid of. Moreover, if you choose clay roof tiles, the color will keep being as when you installed)

Summary:

• Make your homework and find out for yourself about all the pros and cons of the product you choose to cover the roof.
• Ask as many questions as you can to your contractor. Test his knowledge!
• If it is a roofing contractor, make sure his license is active and if there’s any problems with it or his business.
• References! request as many as you want. Take a tour by yourself through the jobs he has done
• Warranty: how many years and what does it cover.

Being on of the most important parts of a house or building, it makes a lot of  sense to choose products for a roof that are fire proof. This will help, in case of the event of a catastrophe, that the fire don’t expand and damages more the structure. A Class A  roofing product (Norm ASTM C1167) is the best choice for any property.

In this case, roof tiles are the best option. Clay roof tiles do not even need to do any test since it is well known that they will not catch fire and will not be damaged by it. In fact, clay roof tiles or ceramic tiles are fired in kilns to make them stronger, so fire, at this point do not harm the integrity of this product.

Safety is important to everybody, so when making a decision on what to install, think in this characteristic too.

What’s been your experience with clay roof tiles?

Perhaps one of the best things about installing roof tiles are the many choices of accessories to complement the roof. Roof Tile manufacturers usually provide a large variety of end-touches that usually other products like shingles, cedar shingles, composite or metal do not offer.
Accessories like ridge end, eave closures, 3-way or 4-way apexes, top fixtures, lantern tiles, etc. enhances the beauty of the roof and give a unique touch for a finished and polished roof tile look.

Even though they are an option, roof tile accessories certainly have a purpose and a function to perform. for example, a ridge end provides a finish to the ridge line, a closure to it to avoid other agent’s intrusion besides the obvious finish look. Eave closures not only serve as a raiser for the first line of tiles, but also as a barrier for birds and other animals to enter your roof and damage it.

Manufacturers of roof tiles make these accessories in different shapes and colors to match your roof design. Some even custom-make roof accessories to satisfy even the most detailed oriented customer.