BCBM - Unit 2
BCBM - Unit 2
➢ Outline manufacture of brick. Types of brick and clay products in building construction.
➢ Brick for masonry walls.
➢ Roof tiles- pan/ pot tiles, Mangalore pattern tiles.
➢ Flooring and paving- brick tiles, clay tiles, ceramic tiles and vitrified tiles.
➢ Basic principles of masonry with brick
➢ Types of brick bonding.
➢ Mortar, plastering, pointing and finishes for brick masonry.
➢ Structural use of brick masonry in foundation, walls, piers, columns, arches and lintels.
➢ Masonry integrated elements such as openings, cornices and copings.
➢ Structural use of brick for roofing as Madras Terrace.
➢ Introduction to innovative and composite construction using brick and clay products -
prefabricated brick panels, precast curved brick arch panels, reinforced brick/
reinforced brick concrete slabs, prefabricated floor/ roof using structural clay units,
Hourdi block roofing,
➢ Understanding construction principles and procedures through sketches/ drawings/
models / site visits/ documentation.
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MANUFACTURE OF BRICKS
The manufacture of bricks is carried out in a number of stages. It includes the following:
1. Selection and preparation of clay
2. Shaping and moulding of units
3. Drying
4. Burning
1. Selection and Preparation of clay
As a practise, suitable deposits of clay are first located and thoroughly tested for the quality of brick making.
Clay for bricks is prepared in the following order.
a. Unsoiling: The top layer of the soil is taken out. This is because the clay in the top layer is full of
impurities and, hence, it is to be rejected for the purpose of preparing bricks.
b. Digging: The clay which is dug out is spread on level ground, just a little deeper than the general ground
level. The height of the heap of clay is about 60–120 cm.
c. The clay should be made free from stones, pebbles and vegetable matter. If these particles are in excess,
the clay is to be washed and screened, which is considered to be uneconomical.
d. Weathering: The softening of clay is done by exposing it to the atmosphere. The period of exposure
varies from weeks to full seasons.
e. Blending: The clay is made loose and any ingredient to be added is spread out at its top. Blending
indicates intimate mixing. A small portion of clay is taken every time for mixing.
f. Tempering: In this stage, the clay is brought to a proper degree of hardness and it is made fit for
moulding. Water in the required quantity is added and the whole mass is mixed so as to form a mass of
uniform character.
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Moulding
Moulding is the process of making rectangular-shaped brick units from properly tempered
clay. The two types of moulding are
a. Hand moulding
b. Machine moulding.
A.Hand moulding
This is presently the most common method for brick manufacture. This is adopted where
manpower is cheap and readily available. The moulds used for hand moulding are
rectangular boxes made from well-seasoned wood or steel open at the top and bottom.
Hand moulding is of two types:
i. Ground moulding
➢ In this method, the ground is first levelled and fine sand is
sprinkled over it.
➢ The mould is dipped in water and placed over the ground.
➢ The clay is pressed in the mould in such a way that it fills all
the corners of the mould.
➢ Any surplus earth from the top of the mould is removed
using a cutting wire or a metal with a sharp edge, which has
to be dipped in water every time it is used. Ground moulding
➢ The mould is then lifted up and the brick is left on the
ground.
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Pallet moulding :The frogs are made using a pair of pallet boards
and a wooden block. A frog is a mark of depth about 10–20 mm
made on raw bricks during moulding. The frog is provided for
mainly two purposes:
i. It serves as a key of mortar when other bricks are placed over it.
ii. It indicates the trade name of the manufacturer.
Pallet moulding
surface and finishing
COMPOSITION
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ii. Table moulding
In this process, a table is used for moulding of bricks instead of ground. The process
remains the same. Raw bricks are moulded on a table of size 2m x 1m and sent for
further process of drying. Since bricks are table moulded, the end product will be of
better quality with levelled surface and finishing.
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B.Meachine moulding
In this process, the bricks are machine moulded and is carried out by two methods namely:
❖ Plastic clay machine moulding
❖ Dry clay machine moulding
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Drying
➢ After moulding the damp bricks are likely to be cracked and distorted while burning.
Hence the moulded raw bricks are dried before they are taken for the next process of
burning.
➢ For the drying process the bricks are laid longitudinally in batches of width equal to two
bricks. A batch consists of eight to ten tiers.
➢ The bricks are allowed to dry until it becomes leather hard of moisture content about 2%.
Burning
➢ This is the final process in the manufacturing of bricks.
➢ Dried bricks are burnt at high temperature to gain the strength, durability and
appearance.
➢ All the water present is removed at 6500C but they are further burnt till 11000C, since
fusing of sand and lime takes place at this temperature. Chemical bonding takes place
after the temperature is cooled down resulting in the hard and dense mass.
➢ Also bricks are not burnt above this temperature because over burning results in the
melting of the bricks leading to distorted shape.
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Clamp Burning:
➢ First layer of fuel for burning is laid as the bottom most layer with the coal, wood and
other locally available materials. Another layer of about 4 to 5 rows of bricks is laid and
then again a second fuel layer is laid over it.After these alternate layers of the bricks
and fuel, the top surface is covered with the mud so as to preserve the heat.
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Kiln Burning:
Kiln is a large oven used for the burning of bricks. Generally coal, wood and other locally
available materials like cow dung, husk can be used as fuel. They are of two types:
❖ Intermittent Kilns.
❖ Continuous Kilns.
Intermittent Kilns: These are like the cyclic kind of kilns, because in these kilns only one
process can take place at one time. Various processes which take place in the kilns are
loading, burning, cooling and unloading of bricks. There are two kind of intermittent kilns
namely
1. Up-draught Intermittent Kilns
2. Down draught Intermittent Kilns
1. Updraft kilns are those in which the
flame is introduced into the bottom of
the kiln, at or below floor level, and
exhausted out the top.
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2. Down draught Intermittent Kilns
➢ Downdraft kilns are designed to force the flame and heated air to circulate through the
kiln.
➢ Flame is introduced at the bottom of the kiln and naturally flows upward. The
construction forces the flame back downward, to exhaust at the bottom of the kiln.
➢ Downdraft kilns consist of four main components:
➢ the firebox, the stack area, the damper, and the chimney. The addition of the chimney
helps create draw or air flow.
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Continuous Kilns:
➢ These kilns are called continuous because all the processes take place simultaneously.
➢ They are used when the bricks demand is more in a short period of time. It is a fast
method of burning and bricks burning are completed in one day itself.
➢ There are two well-known continuous kilns namely
❖ Bull's Trench Kiln
❖ Hoffman's Kiln
Bull's Trench Kiln
AR 3421 - BUILDING CONSTRUCTION WITH BASIC MATERIALS Compiled byAr.. Divya.D M.Arch/PCAP
Hoffman's Kiln
AR 3421 - BUILDING CONSTRUCTION WITH BASIC MATERIALS Compiled byAr.. Divya.D M.Arch/PCAP
Types of brick and clay products in building construction.
AR 3421 - BUILDING CONSTRUCTION WITH BASIC MATERIALS Compiled byAr.. Divya.D M.Arch/PCAP
Types of brick and clay products in building construction.
1. Sun-dried bricks
➢ Unburnt bricks or sundried bricks are the first and most basic examples of bricks. The
process of making these bricks lies in the name itself.
➢ Not burnt but dried in the sun for hardening, often used in rural areas or temporary
constructions. They are not as strong, have reduced fire and water resistance, and
hence are best when left to temporary structures in our list of types of bricks used on
construction.
2. Burnt clay bricks
➢ The most widely used among the types of bricks used in construction, gaining it the
name ‘common brick.’
➢ Used in the construction of important structures such as columns, walls, and the
foundation of the building. They come mainly of four types:
•First-class bricks (best quality bricks)
•Second-class bricks (moderate quality)
•Third-class bricks (poor quality)
•Fourth-class bricks (over-burnt and in irregular shape)
AR 3421 - BUILDING CONSTRUCTION WITH BASIC MATERIALS Compiled byAr.. Divya.D M.Arch/PCAP
Types of brick and clay products in building construction.
First-class bricks (best quality bricks)
➢ Well burnt
➢ Having smooth and even surfaces
➢ Given – Metallic ringing sound
➢ Water absorption shouldn’t more than 20% by weight.
➢ Shouldn’t leave any mark when scratched
AR 3421 - BUILDING CONSTRUCTION WITH BASIC MATERIALS Compiled byAr.. Divya.D M.Arch/PCAP
Types of brick and clay products in building construction.
AR 3421 - BUILDING CONSTRUCTION WITH BASIC MATERIALS Compiled byAr.. Divya.D M.Arch/PCAP
Types of brick and clay products in building construction.
3. Fly ash bricks - Raw materials (Coal from Power plant)
•High Strength
Raw materials pour in to pan mixture, Through the conveyor belt the mixture goes in
to hydraulic machine then get a fly ash brick
AR 3421 - BUILDING CONSTRUCTION WITH BASIC MATERIALS Compiled byAr.. Divya.D M.Arch/PCAP
Types of brick and clay products in building construction.
4. Porotherm Brick :
➢ Porotherm is the clay brick which is used for the
masonry works.
➢ It acts a lightweight infill material. Construction
block technology offers a speedier, cost efficient,
environmentally sound alternative to conventional
walling material.
AR 3421 - BUILDING CONSTRUCTION WITH BASIC MATERIALS Compiled byAr.. Divya.D M.Arch/PCAP
Types of brick and clay products in building construction.
5. AAC Brick
What Are AAC Blocks ?
➢ Autoclaved Aerated Concrete (AAC) block is a low-
maintenance precast building material with excellent
thermal insulation and durability.
➢ The heat-insulating properties of AAC blocks keep the
building cooler and prevent outside heat from entering,
resulting in significant savings on air conditioning
costs.
➢ AAC blocks also guarantee savings in foundation load,
structural steel consumption, and mortar consumption.
Types Of AAC Blocks
•Fire Resistant AAC Blocks
•200 Mm AAC Block
•100 mm AAC Block
•Long-lasting AAC Block
•Rectangular Fly Ash AAC Blocks
AR 3421 - BUILDING CONSTRUCTION WITH BASIC MATERIALS Compiled byAr.. Divya.D M.Arch/PCAP
Types of brick and clay products in building construction.
6. FIRE BRICKS
➢ Also known as the refractory bricks. Manufactured from a specially designed
earthing process.
➢ After it is burned, it can withstand extremely high temperatures through its fire-
resistance properties. This is all done without affecting the desires, shape, size, and
compromising strength.
➢ Thus it is one of the common types of bricks used in India, especially in the rural and
dry regions.
➢ This is used for the lining of chimneys and furnaces where the temperature rates are
usually extremely high.
AR 3421 - BUILDING CONSTRUCTION WITH BASIC MATERIALS Compiled byAr.. Divya.D M.Arch/PCAP
Types of brick and clay products in building construction.
7. CONCRETE BRICKS
➢ Concrete bricks are made up of cement, aggregates, and water. They are not used
widely because of the availability of concrete wall panels.
Advantages Of Concrete Bricks
➢ Higher compressive strength than clay bricks.
➢ Provides a very pleasing appearance and can be used for the façade of the building.
➢ Have a smooth finish and thus requires less amount of plastering.
➢ Provide greater fire resistance than clay bricks
Disadvantages Of Concrete Bricks
➢ Concrete bricks shrink and are not suitable for foundations.
➢ The maximum lifespan of a concrete block is only 65 years.
➢ It does not resist acid attack or efflorescence.
➢ The manufacturing process produces greenhouse gases
AR 3421 - BUILDING CONSTRUCTION WITH BASIC MATERIALS Compiled byAr.. Divya.D M.Arch/PCAP
Types of clay products in building construction.
➢ The raw materials used in their manufacture are clay blended with quartz, sand,
chamatte (refractory clay burned at 1000–1400°C and crushed), slag, sawdust and
pulverized coal.
➢ clay products or building ceramics are basically fabricated by moulding, drying and
burning a clay mass.
AR 3421 - BUILDING CONSTRUCTION WITH BASIC MATERIALS Compiled byAr.. Divya.D M.Arch/PCAP
Types of clay products in building construction.
1. Bricks
The oldest building material brick continues to be a most popular and leading
construction material because of being cheap, durable and easy to handle and work
with.
2. Clay Blocks
Clay hollow blocks are 100% natural, green products and are used in building long
lasting homes. They are LIGHT- WEIGHT, HIGH COMPRESSIVE STRENGTH,
THERMAL & SOUND INSULATION GREEN BUILDING PRODUCT. They are
rated by the Indian Green Building Council (IGBC).
3.
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Coping bricks: Itis provided at the top of the wall to avoid dampness. They are specially
designed brick to cover the tops of brick parapet walls. These bricks are made to suit the
thickness of walls on which coping is to be provided.
COPING BRICKS
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BRICK APPLICATION IN BUILDINGS PARAPETWALL
Throat
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Partition walls are usually not load-bearing, and can be constructed out of many
materials, including steel panels, bricks, cloth, plastic, plasterboard, wood, blocks of
clay, terra-cotta, concrete, and glass.
It may be of folding, collapsible or fixed type. If partition walls are load bearing then
they are called as internal wall.
PARTITION WALL
Types of partition walls
➢Brick partition
➢Hollow block partition
➢Clay block partition
➢Glass block partition
➢Wooden partition
➢Straw board partition
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TYPES OF BRICK PARTITION WALL
➢Plain brick partition wall
➢Reinforced brick partition wall
➢Brick Nogging partition wall
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REINFORCEMENT BRICK PARTITION
Installation- At every third or fourth course,the bricks are reinforced with iron
straps 25mm-28mm wide and 16mm thick.
➢ Mild steel bars of 6 mm diameter can also be used in case of iron straps.
➢ The thickness of wall is kept equal to half brick.
Can be of full floor height or restricted to 2000 – 2500 mm.
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BRICK NOGGING PARTITION INSTALLATION :
➢Consist of a framework of timber within which 1/2 brick partition are
fitted.
➢Framework of timber consists of head, sill, vertical members (studs),
horizontal members (noggins), crossed braces and puncheons (studs over
door frame).
➢Studs (100x50 mm), head and sill (100x75 mm) The studs are placed at a
distance of 3 to 4 times of brick length.
➢The nogging pieces are placed at a vertical distance of about 600-900
mm. The crossed braces are provided at intersections.
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CLAY BLOCK PARTITION
Prepared from clay or terra –cotta and it was either solid (200x50x150 mm)
or hollow (300x200x400 mm).
Groves are provided on top,bottom and sides and work as keys to the plaster.
Mud or normal cement mortar isused as a binding material.
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ARCH: Arch isa structure constructed of wedge-shaped unit Itspans an opening to support the
weight of the wall and other Superimpose load.
1. Intrados: This is an inner curve of an arch
2. Extrados: Outer curve of an arch
3. Soffit: Inner surface of an arch
4.Voussoirs: These are wedge shaped units.
5.Crown : Highest part of extrados
6.Abutment: End point of an arch
7. Springer: It is the first voussoir at springing level
8. Pier: Intermediate support of arches in continuation.
9. Ring: It is the circular course forming an arch
10. Span : Clear horizontal distance between the supports.
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ROOF
FILLERSLAB : Filler slabs are one cost - effective
roofing system which is based on the concrete portions
and instead placing filler material there.
FILLERSLAB TECHNIQUE:
➢Filler slab is a mechanism to replace the concrete in
the tension zone. The filler material, Thus is not a
structural part of the slab. by reducing the quantity
and weight of material.
➢The most popular filler material is the roofing
tile.Mangalore tiles are placed between steel ribs and
concrete is poured into the gap to make a filler slab.
The structure requires less steel and cement and it is
also good heat insulator.
FILLERMATERIALS :
➢ Brick
➢ Tiles
➢ Pots
➢ Waste Bottles
➢ Concrete blocks
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FILLER SLAB MECHANISM
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Case study
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Construction Techniques
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AR 3421 - BUILDING CONSTRUCTION WITH BASIC MATERIALS Compiled byAr.. Divya.D M.Arch/PCAP
Types of brick and clay products in building construction.
= 972000
Now divide the volume of brick wall (without mortar) by volume of single brick
10800000 / 2000 = 4860
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