Tuesday, March 5, 2013

How to Make a Very Big Tile Mosaic

After the wall was measured and the design finalized, it was projected at full scale and traced onto large sheets of plastic. This gives us a full-size image we can work off of while we're in the studio.
We were able to do this thanks to the Sculpture Department at Tyler School of Art. We had to turn the image sideways in order to make it work. 

It's big.


The plastic (on the right) is then gridded, and we can easily transfer the image onto the clay. It has to be scaled up slightly, since the clay will shrink about 15% during the process.

Emily started on the birds

The plastic with the full-scale image is hung on the back wall of the studio so we can reference it as we work. On the table, Jennie started working on the tiles for the landscape in the background. 

These are glaze sample tiles of our color palette

Tiles for the water section of the mural

They're separated and dried, then glazed and fired

Here are some of the water tiles after they've been fired. 

These are color tiles for the furthest grassy area of the mural

Here's one of the birds fired. The lines will be grouted in a dark color when they're on the wall.
In the meantime....

Thanks to the generosity of John Williams and the Ceramics Deparment at Tyler School of Art, we were able to fire all of the large tiles made by the Evergreen students during our workshops

They're big. And fragile.

 
Here they are coming out of the kiln bisque fired. Next step...glazing!




Prepping for workshop #2

Here's how 1500 lbs. of clay gets from Ohio to Philadelphia:

And here's how it looks:

The clay is put through a slab roller to make even sheets. Jennie rolls them:

...and Emily cuts them to size and packs them up:



Keeping track of it all. This is Emily's genius.

Packed up and ready to go!