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    Bricks-Manufacturing and Quality: Building Materials and Construction-I

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    Ifrah Syed
    The document discusses bricks as a building material. It describes how bricks are manufactured through different methods like molded, extruded, and dry-pressed. The molded method uses soft mud and hand molds, extruded uses stiff mud extruded through a die, and dry-pressed uses compressed dry clay. The document outlines the brick manufacturing process and lists qualities of good bricks like uniform color, ringing sound, and high compressive strength. It also provides the typical composition of bricks, with silica being the main component to prevent cracking, and other materials like alumina and lime aiding properties.

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    © All Rights Reserved
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    Bricks-Manufacturing and Quality: Building Materials and Construction-I

    Uploaded by

    Ifrah Syed
    32 views12 pages
    The document discusses bricks as a building material. It describes how bricks are manufactured through different methods like molded, extruded, and dry-pressed. The molded method uses soft mud and hand molds, extruded uses stiff mud extruded through a die, and dry-pressed uses compressed dry clay. The document outlines the brick manufacturing process and lists qualities of good bricks like uniform color, ringing sound, and high compressive strength. It also provides the typical composition of bricks, with silica being the main component to prevent cracking, and other materials like alumina and lime aiding properties.

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    Bmc Bricks

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    The document discusses bricks as a building material. It describes how bricks are manufactured through different methods like molded, extruded, and dry-pressed. The molded method uses soft mud and hand molds, extruded uses stiff mud extruded through a die, and dry-pressed uses compressed dry clay. The document outlines the brick manufacturing process and lists qualities of good bricks like uniform color, ringing sound, and high compressive strength. It also provides the typical composition of bricks, with silica being the main component to prevent cracking, and other materials like alumina and lime aiding properties.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    32 views12 pages

    Bricks-Manufacturing and Quality: Building Materials and Construction-I

    Uploaded by

    Ifrah Syed
    The document discusses bricks as a building material. It describes how bricks are manufactured through different methods like molded, extruded, and dry-pressed. The molded method uses soft mud and hand molds, extruded uses stiff mud extruded through a die, and dry-pressed uses compressed dry clay. The document outlines the brick manufacturing process and lists qualities of good bricks like uniform color, ringing sound, and high compressive strength. It also provides the typical composition of bricks, with silica being the main component to prevent cracking, and other materials like alumina and lime aiding properties.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 12

    BRICKS- MANUFACTURING AND QUALITY

    BUILDING MATERIALS AND CONSTRUCTION-I

    SYED IFRAH ASFAR

    SOALD- SHRI MATA VAISHNO DEVI UNIVERSITY


    BRICKS- AS BUILDING MATERIALS Economical

    Bricks form one of the ‘oldest building blocks’


    Bricks dated 10,000 years old were found in the Middle East.

    A brick is a block of ceramic material used in masonry


    Durable
    construction, usually laid using various kinds of mortar. Reliable

    Advantages of bricks : Low maintenance

    No rotting, melting or buckling. As sidewalks Resonates with


    Safe from termites nature

    No rusting and corrosion


    No denting
    Brick will not fade from the Sun's UV Rays.
    Brick will not be damaged by high winds, rain or hail.
    Low maintenance
    Brick will not devalue.
    Multiple laying
    No limit to personal expression and design Convenience of
    options
    use
    GENERAL CHARACTERISTICS OF BRICKS EXTRUDED- STIFF MUD METHOD

    Brick is made of clay or shale formed, dried and fired into a


    durable ceramic product.

    There are three ways to form the shape and size of a brick:
    extruded (stiff mud), molded (soft mud) and dry-pressed.
    The majority of brick are made by the extrusion method.

    Brick achieves its color through the minerals in the fired MOLDED- SOFT MUD METHOD

    clay or through coatings that are applied before or after the


    firing process. This provides a durable color that never fades
    or diminishes.

    Brick shrink during the manufacturing process as vitrification


    occurs. Brick will vary in size due to the manufacturing
    process. These variations are addressed by astm DRY PRESSED-
    DRY CLAY
    standards. METHOD
    METHODS OF BRICK MAKING
    MOLDED- SOFT MUD METHOD

    Moulded- using soft mud


    From pre-history until well into the 19th- and early-20th centuries and even to
    this date, this method is in use.

    Bricks are hand-made by hand-packing soft, wet, clay paste into wood or later
    metal molds to form one to six bricks at a time.

    In the 1800s, machines mechanized the molding step somewhat, but the basic
    process remained the same.

    Molded bricks are readily identified by a frog, an indentation that typically bears 1.Wetting the 2. Compact filling 3. Scraping extra
    the maker’s name. The soft-mud molding, as well as subsequent drying and insides of the of the mouls mud
    mould
    firing, typically produces slightly rounded arises (edges) and corners and an
    imperfect shape.

    Molds might also be first dipped in water or sand to aid unmolding. Such
    water-struck bricks had comparatively smooth sides but rounded edges and
    corners.

    Making sanded bricks might leave sand or streaks on surfaces or a sand- 4. Removing 5. Turning to other 6. Firing the bricks
    finished texture, if desired. moulds and drying sides and drying in kilns
    METHODS OF BRICK MAKING
    Extruded- using stiff mud and cutting wires
    Brick makers attempted machines in the 1830s, but true mechanization
    had to wait until steam provided the power to thoroughly mix clay and EXTRUDED- STIFF MUD METHOD

    ingredients, then manipulate it as a stiff paste.

    Water in the range of 10 to 15 percent is mixed into the clay to produce


    plasticity. After pugging, the tempered clay goes through a deairing
    chamber that maintains a vacuum of 15 to 29 in. (375 to 725 mm) of
    mercury. De-airing removes air holes and bubbles, giving the clay
    increased workability and plasticity, resulting in greater strength.

    Here a drier, stiff paste is extruded through a die (like making pasta) to
    produce a continuous clay ribbon that is then sliced into bricks (like
    cheese) by wires on a rotating wheel.

    The wire may cut off bricks at their sides (side-cut bricks) or ends (end-
    cut bricks). Bricks so produced are very consistent in composition, with
    precise sides and edges due to the knifelike wire.

    Extrusion is the dominant process today. The die also makes possible
    textures in the brick face or holes in the body that reduce weight.
    METHODS OF BRICK MAKING
    Dry-pressed bricks- using dry clay
    Next development in brick-making was to all but eliminate
    water by compressing dry or semi-dry clay into molds
    with the immense pressure of hydraulic machinery.

    This dry-clay process not only obviated the need to dry


    bricks before firing, expediting manufacture, it enabled
    bricks of exceptional density and detail.

    Pressed bricks are noticeably heavy, hard, and smooth,


    with sharp edges and shapes, and therefore ideal for
    face brick.

    This process is particularly suited to clays of very low


    plasticity.

    Clay is mixed with a minimal amount of water (up to 10


    percent), then pressed into steel molds under pressures
    from 500 to 1500 psi (3.4 to 10.3 MPa) by hydraulic or
    compressed air rams.
    DRY PRESSED BRICKS
    BRICK MANUFACTURING PROCESS

    Preparation of Clay or Brick


    earth
    Unsoiling- to remove impurities of
    organic matter in top soil up to 20 cm.
    Digging:- Clay is dug out & laid on
    leveled ground a little below the general
    surface.
    Cleaning- stone, vegetable matter
    removed. Weathering- cleaned earth is
    spread and exposed to weather for few
    months.
    Blending- mixing of clay/sand/other
    material.
    Tampering- water is added to clay and it
    is kneaded.
    BRICK MANUFACTURING PROCESS

    Moulding
    Hand moulding.
    Machine moulding.

    Drying: 7 to 14 days.

    Burning at 750. C to 1000 . C.


    Clamp burning
    Kiln burning
    SIZE VARIATION

    Because clays shrink during both drying and firing, allowances are made in the forming process to
    achieve the desired size of the finished brick.
    Both drying shrinkage and firing shrinkage vary for different clays, usually falling within the following
    ranges:
    Drying shrinkage: 2 to 4 percent
    Firing shrinkage: 2.5 to 4 percent

    Firing shrinkage increases with higher temperatures, which produce darker shades. When a wide
    range of colors is desired, some variation between the sizes of the dark and light units is inevitable.

    To obtain products of uniform size, manufacturers control factors contributing to shrinkage.

    Because of normal variations in raw materials and temperature variations within kilns, absolute
    uniformity is impossible. Consequently, specifications for brick allow size variations.
    QUALITIES OF GOOD BRICKS

    The bricks should be table-moulded, well burnt in kilns, copper-coloured, free from
    cracks and with sharp and square edges. The colour should be uniform and bright.

    The bricks should give a clear metallic ringing sound when struck with each other.

    The bricks when broken or fractured should show a bright homogeneous and uniform
    compact structure free from voids.

    Brick shall not break in to pieces when dropped from height about 1 meter.

    The brick should not absorbs water more than 20% by weight, for first class bricks
    and 22% by weight for second class bricks, when soaked in water for a period of 24
    hours.
    QUALITIES OF GOOD BRICKS

    Brick shall have low thermal conductivity.

    Brick shall be sound proof.

    When soaked in water for 24 hour, brick shall not show deposit of white salt when
    allow to dry.

    The bricks should be sufficiently hard. No impression should be left on brick surface,
    when it is scratched with finger nail.

    Brick shall not have crushing strength less than 55kg/cm2 .


    COMPOSITION OF BRICKS

    FUNCTION- Prevents brick from shrinkage, cracking & warping.


    Up to 60%
    SILICA Effect of Excess:- Makes brick brittle and useless

    FUNCTION- Absorbs water and imparts plasticity to clay so that it can properly molded
    20-30%
    ALUMINA Effect of Excess:- Shrink and warp during drying & burning.

    MAX 5% FUNCTION- Binding particles together. It allows sand to fuse or to melt during burning.
    LIME Effect of Excess:- Cause to brick melt and loose it’s shape
    FUNCTION- Imparts color. It helps to fuse the lime & sand during burning.
    5-6%
    OXIDE OF IRON
    Bind particles to give hardness & Strength.
    Effect of Excess:- Bricks becomes dark blue
    1% FUNCTION- Decrease shrinkage. Gives yellow tint to brick.
    MAGNESIA
    Effect of Excess:- Decay of Brick

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