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| This section
provides detail on the production of hand and machine
made clay roof tiles as well as valuable technical
information. |
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- The hand made process begins with the digging and
weathering of clay over a period of at least 12 months.
- The
clay batt is placed into a mould, pummelled on by
hand, the excess clay wired off and a punch
brought down which forms the nib and impresses
from the strike plate the company name and the maker's
identification mark. Two nail holes and a manufacturing
identification code are also struck.
- A master tile
maker will produce 2,000 standard
size tiles each day, under half that number
if making special tiles such as unders and overs, which
require
the clay being cut to shape and formed over
a
wooden mould. The tiles are stored on individual
trays for
at least 24 hours in a warm room to remove
excess moisture and then put into a drying chamber
where
the moisture is gently removed. During this
process, the tile shrinks by 7%.
- The dried tiles are
again checked for quality before
being set onto a kiln car which is moved
into a pre-kiln dryer to remove any final moisture,
being placed
into a kiln where the final firing process
takes place.
- The temperature in the kiln is raised
to in excess of 1,000 degrees centigrade during this
process;
the tile shrinks by a further 6%. When
cool enough to be handled, each individual tile is
checked for
quality before being placed into a crate
to be transported to the customer.
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