What is Porcelain and how is it made?
Porcelain is a generic term for a form of engineered stone created from kaolin – a soft, white, fine-calibre, mineral-based clay. It is bonded with other minerals in a process that involves extremes of pressure and kiln-fired heat. The resulting surface material is a rigid, durable man-made stone formed into large format slabs and/or cut into smaller scale tiles.
It is heat-resistant, non-porous (thus waterproof and stain-proof), and resistant to both UV light and general wear and tear. It is generally considered a higher quality surface material than engineered Quartz.
Surface designs are added during the manufacturing process, using digital printing techniques and mineral-based pigments: these can mimic the markings of a variety of other materials – including natural stone – to an almost impossible-to-tell-the-difference degree of accuracy.
Design Implications when choosing a Porcelain Surface
Image:
A built-up edge with crisply mitred corners and a gently tactile bevel where the countertop joins the front edge and falls to the floor in a waterfall style ‘drop’.
This edge detail adds to the apparent depth of the countertop, and enables the flow of the marbling to read as it would for a naturally marbled stone.
With a few technologically advanced ‘4D’ exceptions – where a built-up design can cover multiple surfaces and/or run through the stone – surface design in Porcelain is often purely ‘skin deep’. This means that when you cut through the slab, the stone underneath remains white.
Edge profiles for Porcelain may, therefore, require some special consideration in their design detailing – which may, in turn, add to the cost of fabrication.
Image:
Spot the partially shown book-matched (butterfly-style) join that travels the full length of this backsplash.
The join is matched around the floating shelf on the wall, and across the countertop surface to where a built-up edge meets the elegant recessed handles of bespoke under counter cabinetry
Patterns and Matching
As for all engineered stones, slab sizes vary by brand and are fixed by their manufacturing process – while slab sizes may be large, joins are sometimes required depending on the breadth of the design and how the stone is to be laid (vertically, or horizontally).
However, with more predictable patterning than with a natural stone, and where edge-to-edge matching has been factored in to the manufacturing process, it can be easier to manage joins than is possible with a natural stone without these affecting the visual flow of the markings.
If book-matching has been factored into the manufacturers print process, joins can also be used as means of creating some dramatically symmetrical effects.
Porcelain can be creatively used, as it has been in this display, for some exceptional design detailing.
Matt finished ‘Pietra Gray’ Porcelain stone: used as countertop, backsplash, side panels, and floating shelf. A dropped fascia to the sink recalls traditional butler sink styling, further enhanced by the cladding of the internal surfaces of a specially created watertight sink unit. With no joins apparent, it’s as if the whole had been carved out of a single piece of stone.
How do we choose Porcelain surfaces for a project?
Not all porcelain slabs are created equal – quality of ingredients, design and manufacturing practice can be variable and is often reflected in brand reputations and, of course, price.
With a wide variety of choice available and many years experience of understanding quality, aesthetic effects and the importance of detailing, we take pride in the quality of any porcelain that is specified in our projects.
Finishes & Applications
Porcelain is as at home in a bathroom as it is in a kitchen and can be used on walls, floors, countertops and vanity units. Finishes vary from matt or satin to polished gloss.
- High gloss polished surfaces bring with them beautiful reflective qualities but are not suited to all uses (they may be slippery when wet!) and, in spite of the high level of hardness of the material, will commonly be prone to scratching over time.
- Matt surfaces diffuse light, look and feel softer than gloss, and are less inclined to obvious scratching.
Pros & Cons
- Porcelain stone can be more lightweight than its natural equivalent.
- It has a very high degree of heat resistance, although still may not always be totally resistant to all thermal shocks (from hot to cold, or vice-versa) – so we normally advise some caution and the use of protective heat mats for pans taken directly from the hob or the oven.
- With significant resistance to frost and UV light, Porcelain can also be used outdoors.
- The cost of porcelain (to supply and install) will vary: according to the quality and quantity of material required, and to the time and skill required to fabricate to desired specifications and to transport and install on site.
Sustainability
Recyclability:
Porcelain is a recyclable material – in that its components are purely mineral, with no resin required in its bonding (unlike, eg, engineered Quartz). As a solid composite stone, it cannot be converted back to its individual component minerals, but it can be recycled as an aggregate, and porcelain stones may contain recycled elements.
Manufacturing Implications:
The raw materials used to create Porcelain require extraction and transportation to site, and processing for manufacture includes the application of extreme heat to form the slab. The global heating effects of manufacture are thus significant compared with natural stone that come ready ‘manufactured’ by the forces of nature.
A Day True View
Porcelain is an elegant material that can contribute an element of refined glamour and timeless appeal to an interior. Its hardwearing good looks may be best suited to those who love a natural look but want the ageing-resistant factors of a cosmetically manufactured, man-made material.
If you would like to talk to us about a design for your home, click on the Contact button below to arrange for a free design appointment with one of the Day True design team. We look forward to meeting you in person!
