In this episode of Made Here, you’ll get an exclusive peek into the tile-making process.

The expert masons who produce India’s colorful Athangudi tiles—known worldwide for their sturdiness and shine—carefully guard the secrets of their craft. The sustainably sourced materials required to make these handmade tiles have special qualities that add to their beauty. In this episode of Made Here, you’ll get an exclusive peek into the tile-making process.

Athangudi tiles have been made in the Tamil Nadu region of southern India for more than 200 years, Alex Selva, owner of the Selva Factory, which has produced the tiles for four generations, tells Popular Mechanics. “It was started by a particular community and caste of people,” he explains.

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The village of Athangudi is known for its unique sand. Flecks of mica and silica give the tiles their shine and smoothness. Some 50 villages take part in manufacturing Athangudi tiles and each one uses Athangudi’s sand and water. The manufacturer in this video has a unique story.

The legacy of Athangudi tiles dates to the eighteenth century. Selva’s forefathers began the craft based on their experience in the lime masonry and sculpting industries: “My grandfather founded this current factory, and he was responsible for popularizing this tile all over the country.” The younger Selva would go on to study engineering but returned to his family’s business so that he could continue its legacy.

A growing interest in the tiles allowed their business to expand far and wide, and they now ship their products internationally. The people of Chettinad, a village in the Tamil Nadu province, are traditionally traders and accustomed to international travel for inspiration. The Chettyars brought back various well-made products, like glass from Belgium and globes from London.

Due to these varied influences, Athangudi tiles transformed over time. “Traditionally, the tiles were only black, gray or white,” Selva says. While the Chettyars’ travels inspired bright colors and intricate designs, the designs themselves were uniquely local and feature elements and influences tied to the region.

Athangudi sand is unique. “We don't have riverbed sand here,” Selva says. “It is just sand from the forests and the surrounding area.” The sand’s high laterite content means the tiles will never lose their shine, even with use over time. Due to government regulation, Athangudi sand is not allowed to be mined in truckloads. Masons cart sand to the factory using bullock carts, which carry a fraction of what the trucks are able to transport.

The tiles are crafted almost entirely by hand, without the help of large-scale machinery. A pair of skilled tile workers can produce as many as 200 tiles in a single day using only a scooping spoon to pour the colors, a small shovel for the cement mortar, and a flat wooden plate to compress it at the end. “The whole process, from materials to finished product, takes anywhere between 20 to 40 days,” Selva says.

Once the sand is brought to the factory, it is sieved once and then mixed with colored pigment and different types of cement to make the color layer. The tile workers then sieve this colored mixture again to ensure it has a fine texture. In the last 10 to 15 years, Selva’s company incorporated a machine to mix the color pigment with the sands of Athangudi. All colors—except white—are mixed and ground in this mixer.

The tile maker starts with a 5mm glass base. An outer frame establishes the dimensions of the tile and is placed on top of the base. The frame is then topped with a brass pattern mold, which is specifically designed to survive the wet tile-making environment. Next, the mason pours colors into the frame according to the design. The tiles are typically adorned with flowery patterns referred to as “Kannadi Poo-Kai,”, which translates to “glass flower stone.”

Once the color layer is laid, a dry mix of sand and cement is spread on top. The mason then fills the remainder of the mold with a wet mortar of cement, sand, and water. Finally, they compress the tile together with a plate, giving it a smooth, sturdy base for a seamless finish.

The tiles are left to dry outside for the evening and are then soaked in water the following day, for up to three days. Depending on the weather and season, the drying process can take one to three weeks. Once the tile has dried, the tile worker removes the glass from the tile and dries it. The glass is usually washed with water and a small amount of sulfuric acid, which removes stubborn debris. The mason then sands the edges of each tile to remove any rough spots and stores the finished product in stacks.

“Each tile is made to order,” Selva explains. “If they are stored for too long, they start losing their shine and the edges develop a different color compared to the center of the tile.”

While the traditional methods of Athangudi tile-making have flourished for more than 150 years, fresh designs are always welcome. The factory’s laborers often introduce new ideas for molds and are constantly looking for inspiration around them. Selva also encourages his clients to bring their own designs to the team and caters to as many requests as the factory can manage.

Athangudi tiles have surprising health benefits, too. Since the tiles are made from cement and sand and are repeatedly soaked and dried, water evaporates from their surface almost immediately. Other stones or tiles, which do not have this same property and stay wet, can cause structural damage and harbor mold. Athangudi tiles also keep the floor cool during the region’s hot summers.

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