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    Brick

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    Marta
    1) Clay is the primary raw material used to make bricks. It must have properties like plasticity and strength when wet or dried. Different types of clay include surface clay, shale, and fire clay. 2) The brick manufacturing process involves mining clay, preparing and mixing it, forming bricks, drying them, firing them in kilns, and cooling and storing the finished bricks. 3) Key steps include grinding and mixing the clay, forming bricks using one of three methods, drying the bricks to remove water, firing them in tunnel or periodic kilns to fuse the clay particles, and allowing the bricks to cool before storage.

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    Brick

    Uploaded by

    Marta
    32 views11 pages
    1) Clay is the primary raw material used to make bricks. It must have properties like plasticity and strength when wet or dried. Different types of clay include surface clay, shale, and fire clay. 2) The brick manufacturing process involves mining clay, preparing and mixing it, forming bricks, drying them, firing them in kilns, and cooling and storing the finished bricks. 3) Key steps include grinding and mixing the clay, forming bricks using one of three methods, drying the bricks to remove water, firing them in tunnel or periodic kilns to fuse the clay particles, and allowing the bricks to cool before storage.

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    1) Clay is the primary raw material used to make bricks. It must have properties like plasticity and strength when wet or dried. Different types of clay include surface clay, shale, and fire clay. 2) The brick manufacturing process involves mining clay, preparing and mixing it, forming bricks, drying them, firing them in kilns, and cooling and storing the finished bricks. 3) Key steps include grinding and mixing the clay, forming bricks using one of three methods, drying the bricks to remove water, firing them in tunnel or periodic kilns to fuse the clay particles, and allowing the bricks to cool before storage.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    32 views11 pages

    Brick

    Uploaded by

    Marta
    1) Clay is the primary raw material used to make bricks. It must have properties like plasticity and strength when wet or dried. Different types of clay include surface clay, shale, and fire clay. 2) The brick manufacturing process involves mining clay, preparing and mixing it, forming bricks, drying them, firing them in kilns, and cooling and storing the finished bricks. 3) Key steps include grinding and mixing the clay, forming bricks using one of three methods, drying the bricks to remove water, firing them in tunnel or periodic kilns to fuse the clay particles, and allowing the bricks to cool before storage.

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    INTRODUCTION

    BRICK
    The fundamentals of brick manufacturing have not changed over time.
    However, technological advancements
    have made contemporary brick plants substantially more efficient and have
    improved the overall quality of the
    products. A more complete knowledge of raw materials and their properties,
    better control of firing, improved kiln
    designs and more advanced mechanization have all contributed to advancing
    the brick industry.
    RAW MATERIALS

    • Clay is one of the most abundant natural mineral materials on earth.


    For brick manufacturing, clay must possess some specific properties
    and characteristics. Such clays must have plasticity, which permits
    them to be shaped or molded when mixed with water; they must
    have sufficient wet and air-dried strength to maintain their shape
    after forming.
    • Also, when subjected to appropriate temperatures, the clay particles
    must fuse together.
    Types of Clay
    Clays occur in three principal forms, all of which have similar chemical
    compositions but different physical characteristics.
    • Surface Clays. Surface clays may be the upthrusts of older deposits or
    of more recent sedimentary formations. As the name implies, they
    are found near the surface of the earth.
    • Shales. Shales are clays that have been subjected to high pressures
    until they have nearly hardened into slate.
    • Fire Clays. Fire clays are usually mined at deeper levels than other
    clays and have refractory qualities
    MANUFACTURING

    • Although the basic principles of manufacture are fairly uniform,


    individual manufacturing plants tailor their production to fit their
    particular raw materials and operation.
    • Essentially, brick are produced by mixing ground clay with water,
    forming the clay into the desired shape, and drying and firing. In
    ancient times, all molding was performed by hand. However, since the
    invention of brick-making machines during the latter part of the 19th
    century, the majority of brick produced in machine.
    Phases of Manufacturing
    The manufacturing process has six general phases: 1) mining and
    storage of raw materials, 2) preparing raw materials, 3) forming the
    brick, 4) drying, 5) firing and cooling and 6) de-hacking and storing
    finished products (see Figure 1).
    Mining and Storage. Surface clays, shales and some fire clays are mined in
    open pits with power equipment. Then the clay or shale mixtures are
    transported to plant storage areas (see Photo 1).
    Preparation. To break up large clay lumps and stones, the material is
    processed through size-reduction machines before mixing the raw material.
    Usually the material is processed through inclined vibrating screens to control
    particle size.
    Forming. Tempering, the first step in the forming process, produces a
    homogeneous, plastic clay mass. Usually, this is achieved by adding water to
    the clay in a pug mill (see Photo 2), a mixing chamber with one or more
    revolving shafts with blade extensions. After pugging, the plastic clay mass is
    ready for forming.
    There are three principal processes for forming brick:
    -stiff-mud, (see Photo 3)
    -soft-mud and
    -dry-press.
    Drying. Wet brick from molding or cutting machines contain 7 to 30 percent
    moisture, depending upon the forming method. Before the firing process begins,
    most of this water is evaporated in dryer chambers at temperatures ranging from
    about 100 ºF to 400 ºF (38 ºC to 204 ºC). The extent of drying time, which varies
    with different clays, usually is between 24 to 48 hours. Although heat may be
    generated specifically for dryer chambers, it usually is supplied from the exhaust
    heat of kilns to maximize thermal efficiency. In all cases, heat and humidity must
    be carefully regulated to avoid cracking in the brick.
    Hacking. Hacking is the process of loading a kiln car or kiln with brick. The
    number of brick on the kiln car is determined by kiln size. The brick are typically
    placed by robots or mechanical means. The setting pattern has some influence on
    appearance. Brick placed face-to-face will have a more uniform color than brick
    that are cross-set or placed face-to-back.
    Firing. Brick are fired between 10
    and 40 hours, depending upon kiln
    type and other variables. There are
    several types of kilns used by
    manufacturers. The most common
    type is a tunnel kiln, followed by
    periodic kilns. Fuel may be natural
    gas, coal, sawdust, methane gas
    from landfills or a combination of
    these fuels. In a tunnel kiln (see
    Photo 4)
    Cooling. After the temperature has peaked and is
    maintained for a prescribed time, the cooling
    process begins.
    Cooling time rarely exceeds 10 hours for tunnel
    kilns and from 5 to 24 hours in periodic kilns.
    Cooling is an
    important stage in brick manufacturing because
    the rate of cooling has a direct effect on color.
    De-hacking. De-hacking is the process of unloading a kiln or kiln car after the
    brick have cooled, a job often performed by robots (see Photo 5)
    PROPERTIES
    The most important properties
    of brick are
    1) durability,
    2) color,
    3) texture,
    4) size variation,
    5) compressive strength and
    6) absorption.

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