How to Expertly Install Handmade Tile with Size and Thickness Variations

Learn the best practices for installing handmade tiles with natural imperfections to achieve a flawless, professional look.

At Clay Imports, we pride ourselves on offering a wide selection of handcrafted tiles made by skilled artisan tile makers. These handmade tiles are unique and full of character, often featuring natural variations in size and thickness from piece to piece. While these differences are an inherent part of the handmade process, they can pose challenges during installation. But don’t worry—when installed correctly, these variations enhance the artisanal charm of your space.

In this guide, we’ll walk you through how to expertly install tiles with size and thickness variations to achieve stunning results.

• Why Do Handmade Tiles Have Size and Thickness Variations?
• How to Install Handmade Tile with Size Variations: The Grid Method
• Managing Thickness Variations
• Achieving a Professional Finish
• Final Tips & Resources

Why Do Handmade Tiles Have Size and Thickness Variations?

All handmade tiles exhibit variation—not only in color but also in their dimensions and thickness. These differences occur due to the way tiles are placed in the kiln, where they are exposed to varying levels of heat. As a result, no two tiles are exactly the same.

These variations are not defects, but rather a testament to the authenticity and craftsmanship behind each piece. To get a feel for this natural uniqueness, we highly recommend ordering samples before making your final purchase.

How to Install Handmade Tile with Size Variations: The Grid Method

Traditional tile installation techniques won’t suffice when working with tiles that vary in size. Even slight differences can become more pronounced over multiple rows, making it difficult to maintain straight lines. That’s why we recommend using the Grid Method.

Steps to Install with the Grid Method:

1. Create a grid on your subsurface using pencil, chalk, or laser lines.
2. Apply adhesive to one grid space at a time.
3. Drop the tile into the center of the grid. Make sure the grid space is slightly larger than the tile to allow for adjustments.
4. To achieve ¼-inch spacing, make each grid space about ⅛ inch larger on each side. When tiles are placed side-by-side, the spacing will naturally total ¼ inch.

Using this method helps distribute size variation evenly across the entire layout rather than accumulating inconsistencies on one side. It keeps grout lines consistent and prevents jagged lines.

Pro Tip: If needed, use wedge spacers—especially on vertical installations—to keep tiles from sliding out of place.

Managing Thickness Variations

Installing tiles with thickness differences requires precision. Here's how to keep your surface level:

• Apply adhesive one tile at a time, focusing on each individual grid space.
• Adjust adhesive depth based on the tile’s thickness.

Design by Brooke Irwin

What to Do Based on Tile Type:

Pillow-top tiles: Add more adhesive to the raised center to prevent sinking.

Thinner tiles: Apply additional adhesive to the back of the tile for elevation.

Thicker tiles: Either press them firmly into the adhesive or remove a small amount from the surface to level it out.

The key is to ensure each tile is fully supported and flush with its neighbors to maintain a smooth, level surface.

Achieving a Professional Finish

By using the Grid Method and carefully managing adhesive for thickness variation, you can create a level, professional-quality tile wall or floor. Each variation will be confined within individual grid spaces, leading to a stunningly crafted, one-of-a-kind installation.

Final Tips & Resources

In summary:

• Use the Grid Method for consistent tile spacing and alignment.
• Adjust adhesive depth for each tile to account for thickness variations.
• Review all tiles upon delivery, and consult with a professional tile installer to plan for the best results based on your unique project.

For more detailed guidance, be sure to check out our Installation Guidelines and explore our Clay Care collection for the best tools and products to maintain your tiles.

Got questions? Contact us—our expert design staff is always happy to help you bring your tile vision to life.

🛠️ Note: Since tile installation directly impacts the final look and longevity of your project, Clay Imports does not offer a warranty once the product has been installed. Please inspect all tile upon receipt and notify us of any quality concerns immediately. This guide is a general resource; always consult your tile installer for project-specific recommendations.