If it isn't tiled, it isn't finished!
by Roger Faris
John J. Cosfol must have been delirious with joy when the space shuttle was first unveiled. This craft of the future is covered with a high-tech version of a product from the ancient past. John is a tile expert and enthusiast who would like to fasten baked earth to most of the surfaces in our lives. He knows about special adhesives and methods which allow tile to be stuck to almost anything. I'd like to award him one of those genius grants and turn him loose on the world. I would expect, at the least, for the planet to become highly decorative and durable.
John occasionally volunteers to explain his love of this material and share his knowledge about how to make a tiling project successful. The information is particularly important since tiled surfaces are relatively expensive and long lasting. Mistakes are not easy to correct. In fact, John says the usual remedy for a bad tile job requires the vigorous use of a sledge hammer.
The tile classes begin with some gorgeous show-and-tell. Samples from around the world are circulated and admired while John explains differences in types of clay, glazes, sizes and production methods. Knowledge of these and other facts affect our ability to make a good choice of material for a particular application. As he shows some photos of particularly inspiring work we begin to realize that tilework can also become artwork.
We are taught how to prepare the surfaces that we want to cover with tile. While there are organic based adhesives which can secure tiles to many other materials, John prefers to use cement backer board products and cement based tile setting compound for most work. These are compatible with tile in many important ways, and are not damaged by water. We are also cautioned to make sure that walls are plumb and square, and that surfaces are flat. Floors also need to be made strong enough to resist deflection that could crack tiles or grout joints.
Next we learn about layout. It's best to adjust the position of the tiles so that very narrow pieces are avoided. They're hard to cut and usually don't look right. John shows us how to plan, measure, and draw lines to achieve the best aesthetic results. He also explains important details, such as how and why to properly caulk between a tub and tile wall.
We're ready for tile setting. John has experience with the old mud-set methods and the newer thin-set technology because he's been involved with this business for a long time. His apprenticeship in the craft was in his home town of Philadelphia, where standards of workmanship are high. People who know John also suspect an old world link to tile which is embedded in his genetic code. Local bio-tech firms have been hoping that Cosfol will submit samples of his DNA for further study.
Grouting is another critical stage. Choosing the right grout, mixing it to the right consistency, and properly forcing it into the joints are all part of the recipe. After a slight curing of the material, excess grout is removed with a special sponge that is available at tile suppliers. John wipes the flat side of the sponge diagonally across the joints and rinses it after each pass. He uses two buckets. The first gets most of the grout out of the sponge. After the second rinse (in the clean water bucket) John pretends the sponge is his worst enemy and he has him by the neck. This gets it pretty dry. The final cleanup of the hazy film is done the following day with a terricloth towel.
Cement based materials are made weaker if dried too rapidly. A fan blowing air on new grout is a sign that someone is in a hurry to apply the grout sealer and be done. This sort of thing gives Seattle its reputation as the land of amateurs. Grout should be allowed to cure slowly and thoroughly. Cover windows to protect it from direct sunlight, and cover new floors with brown kraft paper. Tile demands some patience. John Cosfol has traveled to see beautiful tile work from hundreds, even thousands of years ago. It made him a believer in doing it right.
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