The Difference Between Terracotta and Saltillo Tiles

Saltillo tiles are produced exclusively in the town of Saltillo, Mexico and in the same way that sparkling wines can only be called Champagne if they are from the Champagne region of France, sun-dried terracotta tiles can only truly be called Saltillo if They were produced in Saltillo. These tiles are molded by hand from natural clay from the area and then dried in the sun. They are then baked in an oven. Terracotta, which means “scorched earth” in Italian, can refer to any type of natural clay that is shaped into tiles, dried, and then fired in a kiln. Saltillo tiles typically contain Lime Pops that are exposed over time and are often absent in Italian clays. Additionally, Italian, French, and Spanish terracotta can often be more durable due to its extruded manufacturing process.

Terracotta tiles are efficiently made in one of two ways: extruded (machine-made) or hand-made. Both methods will provide good customer service as long as the material is installed correctly and the end user’s expectations are consistent with the product’s intended use. The main advantage of machine-made extruded terracotta is that the clay is compressed and trimmed to size, producing a strong, solid end product. If we compare this to the process of making a snowball, the more we push the snow, the more we compress it, the harder and stronger our snowball is. The less we compress it, the more likely our snowball will break. The machine’s compression process allows less clay to be used during production, which can reduce material and shipping costs. Compression and then firing of the material creates a strong and durable tile that should withstand the daily wear and tear of most consumers.

A handmade material, such as Saltillo, generally requires much more clay during the production process and is made similar to how children make mud pies. Artisans pack the clay in wooden or ceramic frames that define the size of each tile. As tile size increases, the thickness of the material must also increase to maintain the integrity of each tile. An example is that a 12″ x 12″ handmade material may need to be approximately ¾” thick. As the tile size increases to 16″ x 16″, the material thickness should increase to a minimum of approximately 1″ to prevent the tile from crumbling or breaking during the installation process. The added clay required in the handmade process generally increases material and shipping costs.

When a handmade clay tile is fired at a high temperature, the heat draws moisture out of the clay causing several results that must be considered during the selection process. There are small pockets of air in the tile where there was moisture before firing, making the product very porous. This porosity means that this type of terracotta is a poor choice for an exterior application in a colder climate where freeze/thaw conditions exist. Also, tiles frequently bow during firing. The larger the tile, the more exaggerated and pronounced the curl will be during the firing process. The additional thickness of the material and the slope (which increases the absolute thickness) must be taken into account when trying to combine the materials with the existing floors. Handmade material also typically requires a thicker mortar bed during the installation process, which can further complicate flooring thickness challenges. In other words, will the added thickness of the terracotta and setting material allow it to be laid next to an existing floor or carpet without excessive beading?

In the end, handmade or extruded terracotta or Saltillo will hold up well if installed correctly and I have seen many installations hold up for over 50 years. The key to a successful project is the selection of quality terracotta or Saltillo, proper substrate preparation, use of proper installation materials and methods for installation, and completed by a licensed tile contractor who is familiar with this type of facilities.