How handmade roof tiles are made
This is how handmade roof tiles are made at Tudor: sand is thrown into a mould, Etruria Marl clay is pressed in by hand and cut to thickness, and the tile is dried for at least six days before firing at about 1080°C for 33 hours. Each one is then sorted for quality and colour.
Making a handmade roof tile, step by step
Ready-processed clay
Etruria Marl clay arrives processed and quality checked. From here, the work is all by hand.
The mould
Each tile is formed in its own mould.
Sand in the mould
Kent sand is thrown into the mould. It becomes the face, colour and texture of the tile.
Clay into the mould
A lump of clay is thrown into the mould.
Clay for the nibs
Extra clay forms the nibs on the back of plain tiles.
Two knocks
The mould is banged twice to settle the clay.
Pressed
The clay is pressed into every corner of the mould.
Cut to thickness
The back is cut away to leave the right thickness.
Out of the mould
The soft tile is turned out of the mould.
Trimmed
Excess clay is trimmed away by hand.
Onto the drying tray
Tiles are laid out on drying trays.
Six days in the racks
Trays go into racks for at least six days, until 99.8% of the moisture has gone.
Into the kiln
Tiles are fired to about 1080°C, a firing that takes 33 hours.
Sorted by eye
When cool, every tile is sorted for quality and colour.
Ready for delivery
Tiles are palletised, wrapped and stored. The stock area holds over a million tiles.
Why we still make roof tiles by hand
Experience matters. Will, our Factory Production Manager, has worked at Tudor since 1991 and in every department, from clay preparation to colour blending and firing. Modern kiln technology then lets us check every tile and catch imperfections before tiles leave the factory.
Different clay seams fire to different colours. The Roof Tile Association explains how seams such as Etruria Marl behave in its guide to the best visual effect.
Watch the process in our factory videos, or book a factory visit.
Questions about how handmade roof tiles are made
How long does it take to make a handmade roof tile?
Drying takes at least six days and firing takes 33 hours, so a tile takes well over a week from clay to finished product.
What temperature are clay roof tiles fired at?
Tudor tiles are fired to about 1080°C.
What clay are Tudor tiles made from?
Etruria Marl, a dense, high-quality clay, delivered to the factory ready processed and quality checked.
Can I watch tiles being made?
Yes. Factory visits are welcome by appointment: call 01797 320202.
Where to go next
About Tudor Roof TilesThe largest independent maker of handmade-only clay roof tiles in England.- Roof tile making videosWatch tiles and fittings made by hand, tested and fired.
Sustainable clay roof tilesA+ rated for low impact, made locally, 97% of waste recycled.
Handmade plain tilesThe classic nibbed clay tile, 265 × 165 mm, with a deep double camber.
See the tiles before you choose
We deliver samples by hand wherever we can, and you are welcome at the factory in Lydd by appointment.