Our range of clay paving is perfect for creating a beautiful, durable surface with a distinctive geometric aesthetic which is bold, attractive and sustainable. From the initial clay extraction through to the final delivery and beyond, we take pride in every step of the production process of our Dutch clay pavers.
Watch the video and read this guide to learn more about how we do it.
Dutch river clay is the basis of the product. It is a sustainable material that renews organically at a rate of 1cm per year. This natural, non-toxic process makes the supply of clay effectively infinite, and over a large number of years we extract less of the material than is deposited in the rivers.
Wienerberger’s production locations in the Netherlands are almost all located on or near major rivers and canals where the clay is extracted. The clay then travels only a few kilometres by barge and is stockpiled on the riverbank for future use, before the next stage of the process begins. CO2 emissions are therefore limited, and the product remains as sustainable as possible.
Before the process of manufacturing our pavers begins, the clay must be prepared. A magnet is used to remove any metal that may be within the clay, then it is ground down and milled to make the particles a consistent shape and size.
Steam and water are added along with other recycled or secondary-sourced materials to make the final product.
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In addition to the use of renewable clay resources, we also save as many additional raw materials as possible. Residual ceramic material left over from internal production processes is reused, and we successfully recycle waste from brick and tile production for use in new clay pavers.
Crucially, the use of this recycled material does not compromise the quality of the product. The composition of our products is monitored meticulously to ensure that no harmful substances or volatile organic compounds are included.
Dutch river clay is a soft form of clay which dictates how it is moulded into our pavers. Due to the higher water content, the clay is pressed or thrown into a mould, then turned out onto a tray. This is a process that was once done by hand, but in modern factories machines have taken over the process. Now, we can produce tens of thousands of moulded pavers every hour.
Once moulded, the pavers, classed as ‘in their green state’, are then stacked and taken to the dryer. Here, the moisture is drawn out of the pavers over a period of between four to 45 hours depending on the product, using the excess heat from the kiln. The aim is to remove the moisture content of the clay down to below 2% when it will then be ready for firing.
Once the pavers are sufficiently dry, the firing process can begin. In the case of our Dutch clay pavers, the kiln is more than 200m long, making it one of the largest such facilities in Europe. It achieves a temperature of between 1,000 and 1,100 degrees Celsius to give our pavers their durability, strength, fire resistance and colour retention.
More than 100 years of experience producing Dutch clay pavers has given our team knowledge of exactly when to increase or decrease the temperature to create the perfect kiln environment. The final quality of each clay paver is a testament to the experience, skill and diligence of all involved in the production.
Finally, the pavers are allowed to cool down before undergoing a quality assurance inspection. If they pass, they are packed up ready for dispatch. If they don’t, the pavers are separated and recycled either into aggregate or back into the manufacturing process.
Once sent out, our Dutch clay pavers are ready for immediate use by builders, developers and contractors.
As mentioned previously, the clay used for our Dutch clay pavers is a naturally renewing material which is extracted sustainably before being moved to nearby factories for local production. However, these pavers also make other contributions to the sustainability of our natural environment.
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The clay extraction deepens the river floodplains which increases the catchment area and lowers the water level, thereby protecting the local area against floods. This process goes hand-in-hand with the creation of new plant and animal habitat. Over the last 30 years, over 6,700 hectares have seen a biodiversity boost as the river sector and clay extraction work together in the Space for Living Rivers project.
One example is the extraction at Gandelwaard near Loevestein which has lowered the water level by 11cm and created 120 hectares of new, biodiverse river habitat. The 500,000 cubic metres of clay extracted from this project was used as a raw material by the nearby factories.
This focus on sustainability and circularity ensures that our Dutch clay pavers are not only the right choice today, but that they will remain so long into the future.
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