Patio with handmade tiles

Round Patio with Embedded Handmade Tile

Steve J. Noll

Finished patio mirrors the nearby Koi pond.

This site describes a project to build a patio made from cast concrete sections with embedded handmade tiles. It was conceived to 'mirror' the Koi pond/Fountain located on the opposite side of the backyard.

Pond located on the opposite side of the yard.

Before.

Site prep begins.

Site location and preparation.

Testing concrete mixes.

Testing dyes & sealers for UV resistance.

Testing concrete mixes and testing blue dye UV exposure resistance with 40W UV lamps. Concrete mix is a 7-sack mix of white portland with PVA fibers and a high concentration of fortifier.

Cutting bisque tile with diamond bit.

Tiles glazed and ready to fire.

Cutting patterns in ceramic bisque tile with a Dremel with a diamond bit. Glazed tiles ready to fire in the kiln.

Examples of finished ceramic tiles (okay I'm no artist.)

Examples of finished ceramic tiles (okay I'm no artist.) The project took over 70 tiles.

Tiles surfaced with shelf paper and glued face down in the mold.

Mold detail shows routed groves and Teflon rods allow cast sections to interlock.

Tiles surfaced with shelf paper and glued face down in the mold. Mold detail shows routed groves and Teflon rods allow cast sections to interlock.

All sections were cured for a week underwater for maximum strength. Water pH was adjusted daily.

Cured section dyed with special concrete dye. Traditional in-concrete blue dyes turn black in the sun over time.

All sections were cured for a week underwater for maximum strength. Water pH was adjusted daily. White shelf paper protects the tile face and is peeled off during the underwater curing step. Cured sections are dyed with special concrete dye. Traditional in-concrete blue dyes turn black in the sun over time.

Last of three rings of castings is done.

Last sections dyed and ready for final assembly.

Last of three rings of castings is done. Last sections dyed and ready for final assembly.

Assembly on a bed of gravel.

Border footing dug and gopher mech in place.

Assembly on a bed of gravel. Border footing dug and gopher mesh in place.

Nigthtime

Round Patio with Embedded Handmade Tile

Steve J. Noll

(C) 2014 Steve J. Noll