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When it comes to choosing the perfect tiles for your space, it’s important to keep several variables in mind, from those associated exclusively with aesthetics, to those related to practicality. One of these variables is undoubtedly thickness. In this brief guide, we’ll explore the possible options regarding the thickness of porcelain stoneware tiles and how to choose the thickness that meets your needs. In particular, we’ll take a look at thinner options, evaluating the potential and reliability of ultra-thin, over-sized slabs, which revolutionised the ceramic market about twenty years ago.
Thickness is a crucial factor in determining how resistant ceramic tiles are. The general rule is that thicker tiles are recommended for floors rather than for wall coverings, as they better withstand the weight of furniture, impacts, and long-term foot traffic. Nevertheless, thanks to continuous improvements in production technology, this remains true primarily for public spaces, which must adhere to specific national and international standards, more so than for private ones.
In the case of underfloor heating, the thickness of the ceramic (a material with excellent thermal conductivity) can affect how heat is transferred into the room, given that thicker tiles tend to conduct less heat as compared to thinner ones. This is a very good reason to consider using ultra-thin wood-look porcelain stoneware instead of real hardwood, which is an excellent insulator.
Porcelain stoneware is renowned for its durability. This, along with its outstanding practicality and the wide range of aesthetic options available, is what makes it the preferred choice for flooring in high-traffic public spaces, such as shopping centres, train stations, airports, and hospitals.
Stoneware’s durability – an aspect that will be the focus of a future article – depends primarily on its physical and chemical characteristics, perfected by a production process that has, over the past forty years, been honed by a group of Italian companies (including Cotto d’Este) located in the Emilia-Romagna region’s industrial district. However, the thickness of porcelain stoneware also plays a crucial role.
We’ll start here, taking a look at the thicknesses available on the market. Depending on the intended use and the aesthetic requirements of the project, we can categorise tiles into three main groups.
Such minimal thicknesses are associated with ultra-thin over-sized slabs, the product of a manufacturing process that combines the qualities of porcelain stoneware with reduced weight, ease of handling, and versatility. These slabs are produced without the use of moulds and reach truly massive dimensions, making them suitable for a wide range of unconventional uses.
The thickness of a stoneware floor is usually around 10 mm. These tiles come in a wide range of formats and are used for flooring and cladding (including facades) in many residential and public contexts, even those with heavy foot traffic. They provide a good balance of durability, versatility, ease of installation, and affordability.
These are the most durable tiles, designed for outdoor flooring, industrial areas, and areas with heavy foot traffic. They can be installed dry, on sand, grass, gravel, or self-levelling supports. When installed with adhesive on cement screed, they are suitable for outdoor areas where vehicles are manoeuvred. In general, they feature surface finishes with a high degree of slip resistance.
Ultra-thin tiles, particularly large-format slabs with a reduced or minimal thickness, deserve special attention. These were introduced to the market about twenty years ago thanks specifically to Cotto d’Este. Though these are now a popular choice among many clients and designers, back then they were a revolutionary product because they offered much larger formats than those otherwise available at the time (which measured at most 60x120 cm or 90x90 cm) and were also thinner than the standard tiles of that period.
Currently, the thinnest porcelain stoneware tiles range from 3.5 to 6.5 mm depending on the manufacturer. As for formats, we’re talking about tiles with a surface area of around three square metres. For formats that reach 120x278 cm, 100x300 cm, and even 160x320 cm, it no longer makes sense to call them tiles. These are more accurately described as slabs.
Such a reduced thickness might raise some concerns about the material’s durability. However, if you follow the installation guidelines provided by the manufacturer carefully, any doubts quickly prove unfounded. What’s recommended is to carefully assess the technical requirements of the context, especially when installing ultra-thin porcelain stoneware on the floor. After the subfloor and the types of stress that the tiles will have to endure are evaluated, it’s important to hire experienced installers.
This technology has revolutionised the market by providing architects and designers with a material that’s not only durable, but also lightweight, versatile, and easy to work with, while also offering all the intrinsic characteristics of stoneware: frost resistant, easy to clean, waterproof, fire resistant, and resistant to scratches, stains, and commonly used cleaning products. A universal ceramic finish that’s suitable for a wide variety of applications, including installation over pre-existing floors and cladding. This option is truly groundbreaking because it speeds up renovation projects and avoids the hassle of demolition without adding excessive weight to the floors.
Ultra-thin porcelain stoneware has become incredibly popular for cladding kitchen counter-tops and work surfaces. The combination of reduced thickness and large formats is the primary reason for its appeal among kitchen manufacturers, architects, and interior designers. For the world of design in general, using porcelain stoneware to clad was unthinkable up until about twenty years ago. It’s no exaggeration to say that ultra-thin porcelain stoneware has revolutionised the world of ceramics.
Cotto d’Este has been specialising in the production of ultra-thin porcelain stoneware since 2004. The solution, known as Kerlite, comes in three thicknesses: 3.5, 5.5, and 6.5 mm. These measurements include a special fibreglass mesh applied to the back of the ceramic slab. Unique to the brand, this feature was adopted from the very beginning, backed by strong results in mechanical resistance tests. The mesh increases the material’s durability, which, in relation to its reduced thickness, is already extraordinary. This strength is due to the material’s extremely high density, achieved by pressing it with a force of 27,000 tons! This process makes the ceramic easier to work with and safer to handle.
A reduced thickness means less weight. And less weight means an ever broader field of application. Like, for example, flooring for cruise ships and large ferries. It also means, as we discussed in this article, sustainability.
Further confirmation of the revolutionary properties of ultra-thin stoneware is the ability to bend the 3.5 mm thick slab, allowing it to be used even to clad road tunnels.
Cotto d’Este’s catalogue features a variety of thicknesses that range from 3.5 mm thick slabs of Kerlite to 20 mm thick porcelain stoneware tiles for outdoor use, as well as 14 mm thick porcelain stoneware tiles available in standard formats. This last thickness is rather unusual for a market segment in which 10 mm is the standard. However, for Cotto d’Este this thickness has been a defining characteristic ever since the brand was founded over 30 years ago. The reason behind this unconventional and radical choice is explained in this short video.
A distinctive characteristic of some of the brand’s most successful collections is the coexistence of multiple ceramic technologies, resulting in a range of complementary thicknesses. This makes it possible to seamlessly match surfaces in various settings and applications: internal and external flooring, wall coverings and décor, kitchen work tops and furniture. Let’s take a look at which of these collections incorporate all three of the technologies just mentioned.
Lithos offers a fresh take on stone look, blending it with textures typically characteristic of marble. Cotto d’Este’s ongoing research has resulted in a unique and elegant aesthetic, available – as mentioned – in three thicknesses and with five surface finishes to be seen, touched, and felt.
Pura is a ceramic collection that captures the essence of limestone, one of the most attractive and versatile stones in the world. Its unmistakable elegance exalts the stone’s unique mineral qualities, blending them in an original and harmonious way. The result is a texture that’s both balanced and intensely tactile. The collection comes in four colours, four finishes, and six formats, and is also available in three thicknesses: 6.5, 14, and 20 mm.
One of the brand’s long-standing best-sellers, the Limestone collection owes its success to the balanced aesthetic of its stone look and its numerous formats. The synergy between the thicknesses – in this case 5.5, 14, and 20 mm – has also contributed heavily. In fact, Limestone was among the first ceramic collections to offer the same look in three different thicknesses.
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