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Answers to Questions About Why Making Your Own Concrete Tile is Hot Now
HOW MANY DIFFERENT TILE STYLES AND SIZES CAN BE MADE WITH MOLDS?
Concrete tiles can now be made in sizes from 4x4 inches up to 24x24 inches, and larger. They can be made in virtually any color imaginable, and there are many different techniques that can be used to finish them. Almost anything that can be poured with concrete can be poured thin enough to be a tile. There are currently over 200 different styles shapes and sizes of molds for stone, pavers, brick and tile. And new styles are being added all the time. Mold makers also have the ability to make custom mold styles, should they have a special request for a specific style or size of tile or stone.
WHAT ARE CONCRETE MOLDS MADE OF AND HOW LONG WILL THEY LAST?
Most molds are made with polystyrene, industrial ABS plastic, or other plastic blends depending on the application and texture retention desired. They are usually a .060 thickness. We prefer ABS plastic at Olde World for its strength, flexibility and durability. If cared for per easy instructions, molds can last hundreds of pours, depending on the style and size of the mold. Should a mold start to crack in the corners, they can be repaired to prolong their life.
WHAT IS THE LIFE EXPECTANCY OF FINISHED CONCRETE TILE PRODUCTS?
The expected useful life is one hundred years or more. Stone products have been used for thousands of years, with many of the mortared stone roads of ancient Rome still being used today. We recommend that our commercial Producers offer a minimum twenty-year warranty on the products they make as long as they are produced to our normal specifications. When is the last time you saw a concrete sidewalk worn out?
HOW WILL CONCRETE TILE HOLD UP OUTSIDE IN VERY COLD CLIMATES?
Most concrete tile will hold up fine outside in almost any weather as long as it was made and designed for that purpose. Concrete needs microscopic air pockets so the moisture can expand and contract without affecting the solid concrete parts. Our proprietary mix formula, as do other exterior designed concrete tile includes air-entrainment agents to help prevent the product from breaking down under freeze-thaw conditions, like those found in northern climates. Formulas can be adjusted for extreme conditions and special applications by adding extra air-entrainment additive. You want to target for about 5% air content.
HOW MUCH DOES CONCRETE TILE WEIGH, AND HOW THICK SHOULD IT BE?
On average, a 12"x12" tile weighs about four pounds when made with a standard concrete mix. That weight for tile is based on the recommended thickness of between 3/8" and 5/8" with 1/2" being the ideal standard. The tiles can be poured thinner or thicker, depending on the application. As an example, for walls you could pour them down to one-quarter inch thick if desired. If you were using the tile for a steppingstone, as in a garden, you would have to pour it at least 1.5" thick to withstand pedestrian traffic.
WHY ARE YOUR MOLDS SO INEXPENSIVE?
Many mold companies have started on a shoestring and are usually small operations with limited products to offer. There are a number of mold companies that fit this model. Most do not have the benefit of over thirty years experience in mold-making and over seventeen years pioneering the consumer segment of the business. When materials are purchased in large quantities and you have long, ongoing relationships with suppliers like we have, you get the benefits of what is referred to as economies of scale, As an example, we are self-funded--- meaning we owe no one anything. We own our buildings, equipment and land, and are family-run. We keep our profit margins conservative, and grow and expand only as we can afford to. Thus--- we are able to be extremely competitive in our pricing, while offering hundreds of diverse mold products at very competitive prices.
HOW IS THE GLAZED LOOK ACHIEVED IF NO KILN IS USED TO FIRE THE CEMENT TILE?
The various finishes and sheens are created after the manufacturing process through the use of various brush-on sealers. The types of sealers used determine the degree and intensity of the sheen. They range in sheen from a flat stone finish to a deep ultra-glazed finish. The installation and customer preference normally determine which sealers are used, and may be based on where the tile is being installed.
WHAT KIND OF FACILITY IS NEEDED TO MAKE CEMENT TILE?
You really need very little space, and since there is no waste or environmental impact, you can make stone or tile for your own use in a basement, garage, barn, backyard shed, or even outside under normal weather conditions. A wheelbarrow, a shovel, some molds and instructions are the basics needed.
For a commercial operation, you can get by with a two-car garage, but we normally recommend about 1000+ square feet for an efficient production facility. That size plant will handle business growth and production increases for the first year or so. About 1500 square feet is ideal for a commercial sized plant, and should handle growth for the first five years in business.
IS A KILN NEEDED TO MANUFACTURE CONCRETE TILE?
No kiln or other high-energy heat source is needed, and they do not get fired in any way. Tile is cured via a simple method extending the hydration period for as long as possible by covering with plastic to hold the moisture in. Complete Free technical instructions for curing are included with molds and are available on our training website as well.
WHAT IS THE FUTURE FOR CEMENT MOLDS?
With more and more do-it-yourselfers making their own custom-colored stone, paver and tile products to save money and to get the colors they want; mold makers will continue to add new molds and make them easier to get. We constantly add new stone facing, paver, stepping stone and garden molds to our line, as do most other mold makers. By offering these directly to producers, it allows them to have new styles of stone for patios, fireplaces, walls, walks, and any number of other projects--- in the colors they want. The difference in the value added to a home, versus actual cost of what they make is staggering! By making the product they can easily save up to ninety-percent off of normal retail pricing! And the products they make will still be there for their great-grandchildren to enjoy and admire. It can be their legacy.
About the Author
John Panagos founded Olde World Stone and Tile in 1992 to market his Olde World concept and system worldwide. As a pioneer, he's become a recognized authority in the DIY stone and tile mold products segment of the concrete products industry. He's written numerous training manuals, as well as dozens of articles for the industry. For more information, photos and DIY project instructions visit The Mold Store website, or email Info@Oldeworld.com
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