Terra Rustica® Masonry, Covering and Finishings

Two hands take a piece of clay, temper it and shape it in a wooden receptacle. It is as if, without being aware, the act of genesis takes place. We have a shape and after mounting it, we have spirit…the spirit of a high class product.

We produce a large scale of ceramic decorative elements and for rustic look, from visible masonry, floor and plywood elements, to coverings and fence elements, products used both for new civil buildings and for restoration of historical monuments.

Part of these products are manually made, by the technology used since Roman Empire period, the other being mechanically realized, with the help of a press, but generally respecting the rustic look. As a recommendation, for outer spaces should be used only elements of mechanically manufactured floor, those being made of other clay than those manually, with a high resistance to frost-defrost.

Instructions for mounting and maintenance

Due to high absorption of the ceramic products, for an easy maintenance, some mounting rules are to be respected, together with some treatments.

The mounting pof the floor is to be made in a dry concrete screed with a minimal thickness of 4 cm, by thwacking with a rubber hammer, watching that the plates are at the same level. Before this, the product is to be kept submersed for at least 15 minutes. Because the edges of the plates aren’t perfect, there should not be used corners for lines. The lines must be 0.8 – 1.0 cm.

The lines should be filled with a concrete with hardness close to ceramics, in order not to have further problems to polishing. The material from lines is to applied in excess, after becoming hard, due to a higher absorption of ceramics there is the risk that its level gets under the level of the floor. When the material from lines gets consistent, the excess is to be removed and the product is to be washed with a sponge until the surface gets clear.

The passing to the next operations is to be made only after 28 days, time given to the concrete to get mature.

The polishing is an optional operation and can be dry or wet.

The dry polishing is made with a abrasive disk and a lot of dust is made. With the dry polishing is eliminated only the most prominent parts. The obtained surface has two colors: darker where polished and lighter in rest.

The wet polishing is realized with the help of abrasive stones of different hardness, the product being polished almost entirely, but, due to the sand layer not uniform that lays at shaping, no product will be the same as the other, some small imperfections remaining. The product can be used also without being polished.

The washing is the next operation and is to be made only after the floor will be perfectly dry. In the case of dry polishing and of unpolished products, the washing is to be made immediately after mounting and drying process. The washing is made with an acid solution that has the role of neutralizing the solvable salts from clay and from concrete and of removing all the dirt gathered in the previous operations. It is realized with a brush, with circular moves. In the meantime, the gathered wastes are to be removed with a vacuum cleaner, before they deposit on the product. The concrete that hasn’t been hardened and cleaned at time cannot be removed!

The waterproofing is made only on a perfectly dry product. It is made in two successive layers, with a waterproof product based on silicon, specially made for ceramics. For outside will be used a different waterproof product than for inside.

The waxing is made only after the waterproofing product has been totally absorbed. The wax is applied with a circular brush and before drying is made uniform with a (thick) felt.

The final result is up to the way these rules have been respected and to usage of the proper substances. Here must be stated that all these operations can take up to 10 weeks, depending on the temperature. There will not be any work done at a temperature lower than 10° C. The walls that have been prior painted must be protected during these operations.

The visible masonry and the manual plywood can be washed with a brush and can be waterproofed if the requirements demand it. The pieces for ceilings are to be cleaned very well before mounting, washing with acid being recommended after all the work has been done.