Laying, cleaning and maintenance of clay quarry tiles

Background and Applications 

Ketley Bricks are manufactured in a high quality factory in the West Midlands UK which has been operating for 210 years. During this time the company has built up an extensive knowledge of the tile manufacturing process. Ketley Quarry Tiles are manufactured from the proven Etruria Marl clay, which when fired becomes dense, hard wearing and resistant to acids, alkalis, oils, grease and fats. It is the same clay that has stood the test of many decades in the form of Ketley Class A engineering bricks and Dreadnought Roof tiles, still seen in excellent condition in railway bridges, canal locks and roofs across the UK.

The Ketley range of quarry tiles suit most flooring and wall cladding applications indoors or externally, in commercial premises or the home. They are available in a range of natural clay colours from Staffordshire Red, Brown Brindle, Blue Brindle, Brown Antique and Staffordshire Blue. Quarry tiles and brick slips are 18mm thick and demonstrate exceedingly low slip potential in pendulum tests on sliders 96 & 55 and in inclined platform tests in shod conditions, they can be categorised as R11 which means they are not considered to be slippery in wet or greasy conditions, and in inclined platform tests in barefoot conditions, they can be categorised as Category C which is the highest rating for slip resistance. They are ideal for heavily pedestrianised traffic areas, such as external terraces, where continuity from indoors to outdoor paving is desired, light industrial and internally in retail, commercial outlets and the home. Sealers are not necessary but can be used indoors in certain situations.

Laying

Download Ardex guide to fixing Ketley Quarry Tiles
Quarry tiles should be laid on a rigid base, with no voids underneath so that the load applied to them is transferred through to the base. In situations where heavy loads are involved, the strength of the installation can be improved by the use of a thicker paver as the transverse breaking load of a clay paving product is directly related to its thickness where all other factors are equal. It is advisable to select the material to resist the most arduous conditions likely to be imposed during the life of the product.
For a sand and cement base, allow at least 3 weeks before fixing the tiles. and for concrete, at least 6 weeks, preferably 12 weeks drying time should be allowed.
The surface should be hard, sound, clean, free from laitance and dust. It should also be flat with a tolerance of ≤3 mm under a 2m straight edge. Any deviations from this should be corrected using a levelling compound.

UNDER FLOOR HEATING
Ketley Quarry Tiles are fully compatible with both water-based (wet) and electric (dry) underfloor heating systems. Their dense, extruded clay body provides excellent thermal conductivity and heat retention, making them suitable for internal floors where UFH is installed beneath a screed or adhesive bed.

FIXING
Ketley recommends using a tile adhesive such as ARDEX X 7 R. This adhesive is mixed with clean water and applied to the substrate with a suitably sized notched trowel to form straight, ribbed lines. The quarry tiles are then pressed firmly into the adhesive bed at consistent joint widths (6-10mm). The backs of the tiles should be regularly checked to ensure that solid bed fixing has been achieved.

Grouting

Ketley recommends using a flexible grout which is available in a wide range of colours from companies like ARDEX. This product is mixed with clean water to a creamy consistency and worked thoroughly into the joints using a rubber squeegee. As the work proceeds, any excess grout should be removed, residues can be removed with a damp sponge for up to 30 minutes. Any dry film can be polished off with a clean cloth afterwards. If, after this process, there is a hazy mist on the surface of the tiles, this can easily be cleaned off with a grout remover, diluted according to the maufacturer’s instructions.
MOVEMENT JOINTS
These should be installed in accordance with BS 5385-3:2007. Any existing movement/structural joints should be continued through to the surface of the tiling.

Tiles should be cleaned as work proceeds. Such cleaning should be minimal with good workmanship.

Post Fix Builders Clean

After laying, flooring installations can require some cleaning to remove cement and mortar residue from the quarry tiles. In this case, we would suggest the use of a product such as Lithofin KF Cement Residue Cleaner. This can also be used to remove other hardened dirt layers. Due care should be taken during cleaning to avoid contaminating other areas and the product’s health and safety measures should be strictly adhered to.

Cleaning and Maintenance

Ketley Quarry Tiles require minimal routine maintenance. Floors can usually be kept clean by sweeping to remove loose dirt, followed by washing with warm water and a non-soapy, neutral, sulphate-free detergent. Clean, dry surfaces have a naturally low slip potential; most slip incidents occur when contaminants remain on the floor, so an effective cleaning regime is essential for both appearance and safety.
ESTABLISHING AN EFFECTIVE CLEANING REGIME
- Identify contaminants so the correct cleaning agent can be selected.
- Use suitable tools, with dedicated equipment for specific areas if required.
- Schedule regular cleaning, assigning responsibility and timing around pedestrian traffic.
- Provide clear instructions on procedures, detergent use, disposal, spill response, and record-keeping.
- Inspect floors routinely to identify wear, damage, debris, or contamination.
CLEANING METHOD
Cleaning methods vary depending on contamination, surface profile, available agents, and whether mechanical equipment can be used. Regardless of method, all residues must be removed. After cleaning, rinse thoroughly with clean water and leave the floor dry. Failure to rinse can leave detergent or contaminant residues that emulsify when re-wetted and increase slip risk.
INITIAL CLEAN AFTER INSTALLATION
Once grout joints have hardened, tiles may require a light clean using a neutral, non-soapy, sulphate-free detergent, followed by rinsing. Strong detergents should be avoided as they can cause scumming. Tiles should be pre-dampened before applying any cleaner to prevent absorption into the tile body.
REMOVING DIFFICULT STAINS
- Abrasive cleaners, avoiding steel wool, which can leave metal particles that cause rust staining.
- Chemical cleaning using an appropriate solvent; specialist advice may be required for specific stains.
- Bleaching, where suitable, to remove the colour of the stain.
USE OF SEALANTS
Sealing of Ketley Quarry Tiles is not necessary. However, in certain situations such as around a lavatory or shower, where limescale can build up, a sealer can help with cleaning regimes. For more information on suitable sealants, take a look at the Lithofin range of products https://casdron.co.uk Any such treatments applied would detract from the natural slip-resistant properties of the tiles and also provide a medium that would attract and retain dirt and other contaminants and can make regular cleaning more difficult.

Disclaimer The information and recommendations given here are provided as guidelines to good practice. However, since conditions of use and workmanship are beyond the control of the company, its agents and consultants, the information and advice are given without acceptance of any responsibility by the company, its agents or consultants in any way whatsoever.