Large porcelain slabs: innovations and trends for modern floors

Index

1. Introduction
2. Technological evolution in the production of large plates
3. Technical characteristics of XL formats
4. Innovations in surface finishes
5. Technical advantages of XL formats
6. Color and material solutions
7. Technical applications
8. Technical solutions for laying and handling
9. Sustainability in production
10. Future trends and technological developments
11. Conclusions

Introduction

The evolution of the ceramic industry in recent years has seen a gradual push toward the adoption of large stoneware slabs, which have become a symbol of technical and design excellence. Thanks to ceramic innovation, it is now possible to produce XL formats that combine high performance with striking aesthetics.

Initial production challenges related to strength, flatness and decoration on large surfaces have been overcome through new technological solutions. In this context, companies like Sicer have played a key role in making large-format decoration industrializable through glazes, grits, and advanced technologies. Go to the dedicated section.

Technological evolution in the production of large plates

The production of large porcelain stoneware slabs has been made possible by advanced machinery (e.g., continuous presses, electronically controlled kilns) and innovative materials. The introduction of innovative high-performance technologies and products has made it possible to overcome the limitations of standard sizes.

Sicer has contributed to this transformation by developing tailored technical solutions capable of ensuring visual uniformity, dimensional stability and optimal results even on large formats such as 160x320cm.

Technical characteristics of XL formats

Dimensions and thicknesses

Large stoneware slabs available in the market today include sizes such as 120×120, 120×240, 160×320 cm, with thicknesses generally ranging between 6 and 12 mm, up to more than 20 mm for technical uses.

Mechanical properties

Large porcelain slabs exhibit advanced performance in terms of mechanical strength, flexural, abrasion and thermal stability. Their extensive dimensions impose strict management of internal stresses to ensure consistent flatness and safety during handling, installation and end use.

A significant contribution in this area is made by Sicer‘s GRA DRY-LUX technology: a line of dry-application grits designed for mirror lapping of ceramic surfaces. These grits guarantee: 

• Total transparency and compact glass with minimized micro-porosity;
• High abrasion resistance (PEI4 test – 6000 rpm, with weight loss 0.04-0.09 mg);
• Excellent cleanability and chemical resistance (HCl 3% and HCl 18%);
• Controlled coefficient of expansion, ideal for large surfaces and prolonged thermal cycles;
• Optimization of flatness through the use of a fleximetric system developed by Sicer for balancing stresses between substrate and coating.
  
  

These features make GRA DRY-LUX a high-performance technical solution designed to keep large sheets not only aesthetically flawless, but also reliable and durable in high mechanical stress environments.

Enameling and digital decoration

Major product lines include:

• GRA DRY-LUX – transparent grits for dry application, ideal for mirror lapping with high mechanical and chemical resistance;
• GHR – textured grits, perfect for stone or concrete effects with three-dimensional textured surfaces
• .GRS – semi-gloss grits, for surfaces with controlled reflection and good graphic readability;
• GRC – opaque grits designed to achieve deep, anti-reflective aesthetic effects;

These grits are modular and miscible, customizable according to substrate type and production cycle. They offer excellent compatibility with digital technologies, stable adhesion, and controlled fusibility to ensure maximum aesthetic and technical quality even on formats larger than 3 meters.

 Discover all the grits for large slabs on the Sicer website

Innovations in surface finishes

The surfaces of large slabs are now enriched with realistic material effects: marbles, cements, metals, stones. Digital decoration technologies make it possible to achieve deep, three-dimensional results with unprecedented color variety.

Sicer’s NEXT EXPERIENCE SURFACES system, for example, allows for matt, anti-reflective, cleanable, and anti-slip surfaces, thanks to calibrated and additive micro-grits for easy and immediate installation.

Technical advantages of XL formats

Visual continuity and reduction of joints

The greater extension of the slabs allows for a significant reduction in joints, improving aesthetic continuity and reducing dirt accumulation.

Advanced performance

The large slabs, thanks to the advanced production process, offer high flatness, mechanical strength and application versatility, both in residential and commercial settings.

Color and material solutions

Palettes and natural effects

Large porcelain stoneware slabs allow realistic reproduction of natural materials–marbles, stones, cements, woods–on an architectural scale, with a continuous and engaging visual impact. However, to achieve a truly textural and sensory effect, the surface must reflect the three-dimensionality of the inspirational material as well as its graphics.

For this, Sicer has developed Digital Structure: a digital system that can be applied directly in the glazing line, allowing the creation of three-dimensional surface reliefs coordinated with digital decoration.

Digital Structure is available in two versions:

• SDS030 – Reservative (non-material): applied before or after glaze or digital printing, inhibits adhesion of subsequent materials, creating reliefs by subtraction;
• SDS061 / SDS062 – Structuring (textural): with 80 g/m² application, they generate real relief structures from the graphic layout, even on opaque or translucent surfaces.

This technology is compatible with any ceramic system and is ideal for creating highly defined and precise textures, enhancing wood, concrete, natural stone or high-resolution anti-reflective surfaces.

 Learn more about Digital Structure on the Sicer website

Three-dimensional finishes

The surfaces of large slabs are now increasingly sophisticated, thanks to finishes that precisely reproduce the aesthetics and materiality of natural marbles, industrial cements, sedimentary stones or oxidized metals.

One of the most relevant innovations is the dry application of grits on digital glue. This technology makes it possible to achieve extremely precise three-dimensional effects with an exceptional degree of definition and material rendering that is difficult to achieve with traditional techniques.

The process is based on two key steps:

• Selective deposition of digital glue on specific areas of the ceramic substrate (using digital heads with controlled discharge);
• Dry application of grits, which adhere exclusively to the treated areas, resulting in sharp reliefs consistent with the graphic layout below.

This technique is particularly suitable for complex textural decorations, such as those on XL formats. The grits used can be mixed to achieve opaque, glossy, semi-glossy or textured effects, maintaining flatness and optimum adhesion even on large surfaces.Sicer offers specific formulations of technical grits (e.g., GRS, GRC, GHR) that are compatible with this type of application, providing chemical resistance, visual depth and aesthetic continuity.

Technical applications

Large sheets find application in multiple areas:

• Flooring of large indoor spaces (open space, shopping malls, museums)
• Vertical wall coverings
• Kitchen tops, tables, custom furniture
• Ventilated facades and outdoor applications

Each application imposes different technical requirements, from mechanical strength to compatibility with fastening systems.

Technical solutions for laying and handling

Critical issues and solutions

XL sheets require specialized handling equipment (suction cups, frames, balancing trolleys) and suitable installation systems with compatible adhesives and supports.

Sustainability in production

Sustainability in production

Sustainability is no longer an option but a strategic requirement, especially in the ceramics sector, where production processes are energy-intensive and complex. In this scenario, Sicer places the search for low environmental impact solutions at the center of its innovation, contributing in a concrete way to the ecological transition of the entire supply chain.

Notable actions developed for the production of large stoneware slabs include:

1. LOW EMISSION digital inks.

Sicer has designed a dedicated line of low-emission inks developed to drastically reduce the production of volatiles during firing:

• Lower environmental impact during sintering;
• Reduction of air emissions, especially VOCs (volatile organic compounds);
• Excellent compatibility with high-definition digital decoration systems.

These inks not only improve the quality of the working environment, but also represent a step toward compliance with the most stringent international environmental regulations.

2. Water-based digital glue

Another distinctive feature is the use of water-based digital adhesives for dry applications (e.g., textured grits on XL slabs). Compared with conventional systems, they offer:

• Absence of solvents and reduction of chemical risk;
• Controlled evaporation and increased compatibility with high-temperature production environments;
• Excellent adhesive performance even on vertical or textured surfaces.

This technology can be perfectly integrated into existing systems and contributes to the drastic reduction of environmental impact without compromising adhesion performance or the aesthetic quality of the final result.

3. Energy optimization and waste reduction

In the case of large sheets, the optimized production of continuous surfaces makes it possible to reduce the number of firing cycles per square meter and minimize the waste associated with joints or trimmings, while also improving logistical efficiency and the overall energy balance.

Read more here

Future trends and technological developments

New Frontiers

Upcoming developments point to:

• Tactile sensory effects
• Antibacterial and self-cleaning technologies
• Additional size increases
• Integration with home automation or smart surface systems

Sicer continues its investment in R&D to anticipate the needs of a rapidly changing industry, consolidating its role as the technology partner of choice.

Conclusions

Large stoneware slabs today represent one of the most advanced and versatile solutions for ceramic design. Their success is the result of technical research, innovation and attention to market needs.

Sicer, thanks to tailor-made solutions, digital technologies and an international presence, confirms itself as one of the best prepared players to accompany ceramic producers in the transition to large formats.