Installing authentic Zellige tile?

technical

By Lesley Goddin, Editorial Director and Senior Writer

YOU NEED THIS DOCUMENT!

The NTCA Technical Committee meets as a group twice a year, and individually in sub-committees throughout the year to develop papers and documents that support standards-based installation and best practices for tile installers and contractors. These documents and papers then appear in the annual NTCA Reference Manual, published by the NTCA.

One of the recent resources approved for inclusion in the 2024-2025 NTCA Reference Manual was the “Zellige Tile Installation Challenges and Considerations” document. While you can find the complete document in the NTCA Reference Manual this summer, this story will touch on a few key points that those installing Zellige tile need to be aware of.

NTCA Past President Martin Brookes, Director of Installation for Fireclay Tile, headed up the subcommittee that drafted this document together with Armen Alajian, ARTO; Brad Denny, CTEF; Dirk Sullivan, Hawthorne Tile; Frank Donahue, Best Tile; John Cox, Cox Tile; Josh Levinson, Artistic Tile; Mike Micalizzi, Custom Building Products; Sam Bruce, Visalia Ceramic Tile; and James Whitfield of MAPEI.

The inspiration for this document grew from a frustrating experience Brookes had with a large residential contract that specified Zellige tile in two bathrooms. He was familiar with the limitations of the product, so mockups were made and approved by the designer and the tile was installed and grouted.

But the owner had seen the one-foot sample board in the store without grout joints and that’s the look he wanted. “This was not something we had agreed to and was causing friction between all involved including the GC who was trying to mediate the issue,” Brookes said. The owner was intransigent, so the install had to be torn out and replaced (with the GC footing the bill). This time, “we created story poles, laid out each elevation on the floor, photographed and sent to all parties for approval before installing a single piece,” Brookes said. “This was painful and went against my better judgment since having touching tile with high absorbency potentially could blow off the glaze from the bisque. We managed to meet the expectations, but this inspired me to create a working group of tile experts to bring a paper for installers to use when faced with this dilemma. With the help of these individuals, we were able to create a document that will help installers have a voice rather than just their opinion. It’s groups like this that help change the industry for the better and not have the installer feel like they are on their own.”

How closely the client demanded the Zellige tiles be set to meet his expectations, which went against Brookes’ better judgment.

Georgia Ezra is CEO and Creative Director of Tiles of Ezra, which has curated a trusted team of Moroccan artisans and processes for 13 years and who supplied some of the photos for this story. She said, “There is SUCH a vast array of manufacturers and quality in Morocco, so literally one tile is vastly different to another depending on the manufacturing teams – and that even comes down to how well the artisans are paid or treated, as they literally make the tiles by hand. When it comes to handmade tiles, quality is paramount. As interest in Zellige tiles grows, it is crucial for clients to understand what makes these tiles truly unique.

Brookes’ client was expecting that his handmade Zellige tiles would be set this close - and inspired the drafting of the document that will appear in the 2024-2025 NTCA Reference Manual.

“The term ‘Zellige’ is increasingly being used to describe any tile that resembles a handmade product, even if it is mass-produced by machines in other countries,” she added. “However, genuine Zellige tiles are handcrafted exclusively in Morocco, using techniques that have been passed down through generations since the 13th century or even earlier. Inferior imitations lead to a decline in overall quality. It is essential for clients to be aware of where their tiles come from and to ensure that their supplier maintains rigorous quality control standards.”

Zellige kiln work by the exclusive artisan team at Tiles of Ezra. ©Tilesofezra

Document highlights Following are a summary and excerpts from the document, which outlines the unique characteristics of Zellige tiles and the potential challenges installers may encounter during installation.

The document points out the unique nature of Zellige tiles, which are handmade from clay and exhibit a lot of variation in thickness, size, and shape. To ensure a successful install, it’s key to create a template, and to have a grouted mockup approved by all parties involved. This will illustrate the uneven width in the joints, the overall effect of which adds to the handmade charm of the tile and the installation.

In addition to ordering 25% extra stock to account for cutting, breakage and having enough tiles on hand when encountering tiles with unwanted characteristics, the document recommends using adhesives with extended open time, flexibility and strong bond strength to prevent tile movement or cracking. Your supplier can advise whether you need to soak the tiles prior to installation to prevent adhesives from drying out too fast. Also consult your grout manufacturer for guidance on preventing staining and ensuring proper adhesion with sanded grout. Again, a mockup with selected grout type and color is recommended.

Be careful when handling Zellige tiles and especially when creating mitered corners – edges can be deceptively sharp. Wear gloves!

The charm of Zellige is its imperfections that demonstrate its handmade nature – hairline cracks, slight variations in color and glaze – but take the time to distinguish between acceptable “character marks” and potential structural issues before installation. Patience and an eye for detail is essential when working with Zellige, as is discussing the handcrafted nature and limitations of the tile with the client before installation.

A final recommendation is to contact your Zellige tile supplier and request an installation data sheet for specific recommendations.

While they can be challenging to work with, handmade Zellige tile provides a rustic, charming, old-world look with artisan beauty. Following these recommendations for installation can make the difference between a well-performing, beautiful smooth installation and one fraught with disaster. Look for the complete document in the upcoming 2024-2025 NTCA Reference Manual.

${prev-page}

${next-page}