Unity University

Building Materials &

construction I

Lecture V
Brick

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Uses of Brick
• Structural units, bridges, dams, building frame
• Facades
• Acid refractory Lining etc.
Bricks
are one of the most extensively used materials of construction. Their
popularity as building material lies in their
• Strength
• Durability
• Insulating property against heat/coldness and sound
• Being handy to work with.
• Relatively cheaper prices.

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Raw materials:- Mainly manufactured from Clay. Clays are fine-grained
soils that have resulted from the decay of rocks. deposited of fine rock
particles transported by water or wind.
Clay consist of the following chemical element
– Alumina (Al2O3)
– Silica (SiO2)
– Ferric oxide (Fe2O3)
– Lime (CaO)
– Magnesia(MgO)
– Carbon Dioxide (CO2)
– Sulphur trioxide(SO3)
– Alkalies (K2O, Na2O)
– Water (H2O)

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 Clays are generally found mixed with other materials (impurities) that
influenced their properties.
 It Prepared with water (plastic), it can be molded, dried and burnt without
cracking or changing it shape or warping

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Functions of the constituent materials
Alumina
– A fine –grained mineral that makes the major part of clay
– Plastic when mixed with water and is capable of being molded
to desired shape
– On drying – it loses its plasticity becomes hard, shrinkage,
warping and cracking
– When burnt, stronger and harder due to the homogeneity
created by fusion
– Brick of very high alumina content are likely to be refractory
– 20% to 30%

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Silica
• A Course grained of mineral
• It reduces shrinkage and warping in burning
• Hardness and durability introduced
• Large percentage of uncombined silica is leads to brittleness
• Silica fuses only at very high temperature of and hence increases
refractoriness of low alumina clay and makes bricks resistant to heat. the
silica content may rise to 98%.
Lime
– It acts as a flux and lower the fusion point of silica
– Acts as a binder to the clay and silica particles leading to greater strength
– Excess of lime may cause the bricks to melt and lose their shape
– < 5%
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Iron oxide
– Like lime lowers the fusion point of clay and silica.
– Gives color
– Depending on the percentage of iron oxide present in the clay, the
color of the bricks may vary from light yellow to red
– A high percentage may make – dark blue
– If iron is present in the form of Pyrites(sulphide of iron,) it can get
oxidized, crystallized and split the brick to pieces.
– 5‐6%
Magnesia – (MgO)
– Gives the brick yellow shade.
– Minimizes warping of bricks in burning
– Magnesia is present in small quantity (1%)
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Manufacture of brick four basic sages
1. Preparation
2. Molding
3. Drying
4. Firing

Preparation
• Digging out (winning)
• Crashing and/ or grinding and mixing until it is of a uniform consistency.
• water is added to increases plasticity( a process known ‘tempering’)
• Chemicals like barium carbonate that reacts with soluble salt producing an
insoluble product therefore reducing efflorescence in the final product.
• Sand and water added to produce the desired consistency
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Molding based on moisture content there are three kind of processes
of molding
1. Soft mud process
• Clay from shallow surface
• 30% moisture content
• Mechanically forcing wet, soft clay into molds under pressure,
cuts, of excess clay.
• The inside of the mold sprayed or dipped in water to prevent the
clay from sticking.

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2. Stiff-mud process
– It is forced or extruded in a column through dies in a brick making
machine.
– a column of clay is forced into a wire-cutting table, where it is cut
into appropriate length by taut wires.
3. Dry pressed brick
– Relatively dry or non plastic clays
– The material is fed into the machine by hopper, where it is
compressed into mold under high pressure
– It is compact, strong, and well formed

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Drying
– Brick contain from 7 - 30% moisture
– Conventionally they stacked in open sheds for 7 days to 6 weeks
– Under controlled condition, heat, moisture, and air velocity for 2 to 4 days
– Drying enables the bricks to be stacked higher in the kiln and increase firing
temperature more rapidly with out problem such as bloating ( when gases or vapor
are trapped within the brick)

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Firing
– Localize melting (sintering) of clay
– Increases strength and decreases the soluble salt content without loss of shape of
the clay unit.
– Silica and alumina do not melt, since their melting point are very high; they are
fused by lower melting point mineral such as metallic oxides and lime.
Stage of firing are:
100 0C Evaporation of free water
400 0C Burning of carbonaceous matter
700 0C Dehydration 900 0C Oxidation
900 - 1000 0C Sintering of clay

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Control rate of increase of temperature Maximum temperature give rise to
– Having satisfactory strength
– Quality
• Too rapid firing will cause bloating and over burning of external layers
• Too low a temperature impairs strength and durability
• Firing of ordinary quality or common bricks is at 900 0C and for
Engineering brick is greater than 1000 oC

Drawing is the process of unloading a kiln after the bricks are cool. Then
they are sorted, graded, packaged and then to storage
Vitrification is changing in to glass like substance by fusion due to heat.

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Method of giving attractive appearance
a) Texture
• When column of clay leaves the die in the stiff mud process
• Applied by attachments which cut , scratch, brush, roll or roughen the surface
(molding stage)
b) Glaze
• Shiny or glossy surface finish
• Glazes are sprayed on the brick before or after burning

Type of glazes
1. Ceramic glaze – Spraying a coating of a mixture of mineral ingredients on one or more
facing of the brick – Available on any color – Glass like coating
2. Salt glazed (transparent) – A solution of sodium silicate – Transparent and the color of the
brick is presented under a glass
3. Flashing – At the end of the burning stage – By inject natural gas

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Types of bricks
A. Common bricks
– Ordinary red brick , not designed to provide good finish appearance or high
strength.
– The cheapest brick available and most widely used for walls.
– No special color, shape, and texture
B. Facing bricks
– Designed to give attractive appearance,
– Hence they are free from imperfection e.g. cracks
– May be derived from common bricks to which a sand facing and/ or pigment has
been applied prior to firing.
C. Engineering brick
– Design for extra strength and durability
– They are usually highly dense and well fired
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Classification of Bricks
Clay bricks are classified as first class, second class, third class and fourth
class based on their physical and mechanical properties.
First Class Bricks
1. These are thoroughly burnt and are of deep red, cherry or copper color.
2. The surface should be smooth and rectangular, with parallel, sharp and straight
edges and square corners.
3. These should be free from flaws, cracks and stones.
4. These should have uniform texture.
5. No impression should be left on the brick when a scratch is made by a finger nail.
6. The fractured surface of the brick should not show lumps of lime.
7. A metallic or ringing sound should come when two bricks are struck against each
other.

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8. Water absorption should be 12–15% of its dry weight when immersed in cold water
for 24 hours.
9. The crushing strength of the brick should not be less than 10 N/mm2. This limit
varies with different Government organizations around the country.
Uses: First class bricks are recommended for pointing, exposed face work in masonry
structures, flooring and reinforced brick work.

Second Class Bricks are supposed to have the same requirements as the first class
ones except that
1. Small cracks and distortions are permitted.
2. A little higher water absorption of about 16–20% of its dry weight is allowed.
3. The crushing strength should not be less than 7.0 N/mm2.
Uses: Second class bricks are recommended for all important or unimportant hidden
masonry works and centering of reinforced brick and reinforced cement concrete
(RCC) structures.
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Third Class Bricks are under burnt.
They are soft and light‐ colored producing a dull sound when struck against each
other. Water absorption is about 25 per cent of dry weight.
Uses : It is used for building temporary structures.

Fourth Class Bricks are over burnt and badly distorted in shape and size and are
brittle in nature.
Uses: The ballast

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On the Basis of Finish
Sand faced brick:- has textured surface manufactured by sprinkling sand on the inner
surfaces of the moulds.
Rustic brick :- has mechanically textured finish, varying in pattern.
On the basis of burning
Pale brick are under bricks obtained from outer portion of the kiln
Body bricks are well burnt bricks occupying portion of the kiln
Arch brick are over burnt also known as clinker bricks obtained from inner portion of the
kiln.
On the basis of types
Solid:- small holes not excedding 25%of the volume of the brick
Perforated:- Small holes may exceed 25% of the total volume of the rick
Hollow:- the total of holes, which need not be small, may exceed 25 % of the volume of
the brick
Cellular:- Holes closed at one end exceed 20% of the volume.
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Types of bricks according to the Ethiopian standard
Solid bricks are the following three types:
1. Brick without holes or depression (type TS)
2. Brick with holes up to 20mm in diameter each having a total cross
sectional area not exceeding 25% of the base area of the brick
(type TH)
3. Brick with depression not exceeding 25% of the base are having a
maximum depth of the depression not more than 10mm (type TD)

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Fire bricks or Refractory bricks
These bricks are capable of withstanding very high temperatures without melting or
becoming soft.
• Firebricks are manufactured in exactly the same manner as the ordinary bricks
burnt in kilns at temperatures ranging from 1350 0c to 1900 0c.
• Firebricks are the white or yellowish white color and are used for lining the
interiors of fireplaces, ovens, kilns, chimneys and furnaces.

Properties of brick
The essential properties of bricks are:-
- Physical properties,
- Chemical characteristics,
- Thermal characteristics
- Durability
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1. Physical properties
• Shape- rectangular
• Size – 60 mmx120mmx250mm
• Color – red
• Density- density varies from 1600 kg/cubic meter to 1900 kg/cubic meter.
A single bricks (60x120x250) will weigh between 3.2kg to 3.5kg depending upon its
density

2. Mechanical properties
Compressive strength is the most important property of bricks especially because
they are to be used in load bearing walls. The compressive strength of a brick
depends on the composition of the clay and degree of burning.

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3. Thermal properties
The heat and sound conductivity of bricks varies greatly with their density and
porosity. Very dense and heavy bricks conduct heat and sound at a great rate. They
have therefore poor thermal and acoustic (sound) insulation qualities. For this
reason, bricks should be so designed that they are light and strong and give adequate
insulation.

4. Durability
By durability of bricks is understood the length of time for which they remain
unaltered and strong when used in construction. The durability of bricks depends on
a number of factors such as: absorption value, frost resistance and efflorescence.

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Tests for Clay Bricks
Two types of tests are used to determine the quality of building bricks.
a. Field test
b. Laboratory test
a. Field tests: such as appearance, hammer and hardness
 Appearance test is that: shape, plainness, color etc.
 When stroked with hammer, a properly burnt dry brick free from cracks emits a highly
metallic ring.
 The hardness of a brick sample can be checked by scratching its surface or broken section
with a knife or fingernail. A well-burnt brick will be scratched with difficulty.
 A rough test for the strength of the brick is to let it fall freely from a height of about one meter
on to a hard floor. It should not break.
b. Laboratory tests
1. Compressive strength test
2. Water absorption test
3. Efflorescence test and
4. Saturation coefficient test =(absorption after 24 hrs in cold water) / absorption after boiling
for 5hrs
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Characteristics (Qualities) of a good brick
The essential are sufficient strength in crushing, regularity in size, a proper
suction rate and pleasing appearance when exposed to the view.
Size and shape:- it should be uniform in size and plane, rectangular surfaces
with parallel sides and sharp straight edges.(60mmx120mmx250mm)
Color:- it should have a uniform deep red or cherry color as indicative of
uniformity in chemical composition and thoroughness in the burning process.
Texture and compactness:- it should be so hard and stuck together a metallic
sound should be produced.
Water absorbance:- should not exceed 25% of its dry weight when kept
immersed in water for 24hr.
Brick earth:- should be free from stones, organic matter, salt petre etc.
Dropped from 1m height, it should not be broken to pieces.

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Defects of Bricks
Over Burning:‐ if the bricks are over burnt, a soft molten mass is produced
and the bricks loose their shape. Such bricks are not used for construction
works.
Under Burning of Bricks:‐ When bricks are not burnt to cause complete
vitrification, the clay is not softened because of insufficient heat and the pores
are not closed. This results in higher degree of water absorption and less
compressive strength.
Bloating:‐ This defect observed as spongy swollen mass over the surface of
burned bricks is caused due to the presence of excess carbonaceous matter
and sulphur in brick‐clay.
Black Core:‐ When brick‐clay contains bituminous matter or carbon and they
are not completely removed by oxidation, the brick results in black core
mainly because of improper burning.

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• Efflorescence:- This defect is caused because of alkalis present in
bricks. When bricks come in contact with moisture, water is absorbed
and the alkalis crystalize.
• Chuffs:- the deformation of the shape of bricks caused by the rain
water falling on hot bricks is known as chuffs.
• Checks or cracks:- this defect may be caused of lumps of lime or
excess of water.
• Spots:- iron sulphate, if present in the brick clay, results in dark
surface spots on the brick surfaces. Such bricks though not harmful are
unsuitable for exposed masonry.
• Blisters:- Broken blisters are generally caused on the surface of sewer
pipes and drain tiles due to air imprisoned during their molding.
• Laminations:- caused by the entrapped air in the voids of clay.
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Non – Clay bricks
 Concrete blocks
 Fly –ash brick
 Sand-lime or calcium silicate bricks

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