Custom Stoneware Tile Installation Takes Shape

I have been installing the custom tiles in their new home and am happy to report they've found themselves to be quite comfortable there. It was both exciting and a relief to see the design taking shape. Making sure the tiles will fit in their given space is a bit tricky since the shrinkage rate varies from 15-18%. So to allow for this, I made a few extra pieces of differing widths.


I laid out the tiles and prepped the area. Then I slapped some mortar up on the wall. Diving in with the mortar is a sort of free-fall experience, but there's no other way to do it. Piece by piece, like putting together a puzzle, I installed the mural backsplash. (The white spacers keep the tiles from sliding around until they set.) With that installed, I started on the row of hand painted design tiles mixed in with the plain tiles along the entire countertop. Factory made tiles are all identical which makes installation a breeze, but the handmade nature of custom tiles requires some patient manipulation. Then the mortar needs to harden before you can start in with the grout, so I cleaned up and headed home.

Grouting seals the gaps and bonds the tiles together and keeps moisture from getting in. I chose a light sandy tone to blend in with the countertops, but many colors are available and changes the overall affect. The installation process involves pressing the grout in with a float, letting it set while keeping everything wiped down, and finally smoothing it out. For a final touch and added protection, I added some caulk. And that was that.

The sun is rising over the hills this morning as the rooster crows in a newly tiled kitchen.

Custom Kitchen Backsplash, Handmade Stoneware Tiles, A Step by Step Process

I have been busy designing and creating a kitchen backsplash, from deciding on the general layout to planning the overall theme to choosing a general color scheme. It has already been three months in the making. Tiles have to dry slowly which allowed me to carefully consider each step along the way.

First was to discuss what the clients wanted. Based on the location of the house in rural Wisconsin and their outdoor interests, we came up with a list of ideas. I measured and took pictures. I took all the information home and gathered my thoughts. One thing that kept coming back was the rooster trivet they have. The simplicity in the curves and the brightness of colors seemed to fit in well and made its way onto the backsplash that will be installed over the stove. Their love of nature and gardening inspired the tile themes that will run along the countertop, interspersed between plain tiles.

After the designing was finished, it was time to roll out the clay and start cutting. Each batch of twenty-five pounds made only about 35 tiles so I needed to repeat this step several times. When the tiles are initially cut they are too wet to handle without causing warping. They need to be covered with a hard board and allowed to harden. This step takes time, patience, and a lot of space in the studio! Every couple of days I would peek under the board (topped with paint cans for extra weight) and inspect them for moisture content. Finally they were ready for smoothing.

Each tile needs to be refined and shaped along its edge. I use burlap underneath to give some texture that will adhere better to the mortar, but I also turn each over and trim out some additional grooves with a ribbon tool.  Once this lengthy process is over and the tiles are completely bone dry, they can be bisque fired.

Meanwhile, I chose a color palette for the tiles. I wanted a bright, cheery theme without being too gaudy. I bought a new assortment of Amaco matte glazes and made a few test tiles. The background color was the hardest to choose and took me until I had already glazed the rooster mural and each decorative tile to finally realize which it should be. The dark blue in the rooster body was the natural choice. Like the blue of the sky, it would allow the richness of the colors in each design to be highlighted. And the light orange of the clients' kitchen would complement the blue as well.

Each hand carved design needed to be carefully glazed with fine brushes and then covered with wax resist. The wax keeps the background color off of the design. Then each tile was brushed with blue and fired again.

Next up is the installation. I bought some mortar and grout and will head over with all the tiles in the coming week. More pictures of the end result will surely follow. I love making custom orders because I know exactly where and how my work will be enjoyed. Now off to the kitchen - where a 'Guten Appetit' for my custom tile work is waiting!