Brick
Brick
Material?
• NDT*- Non-destructive tests (NDT) are test methods which are used to
examine the hardened concrete structure for their suitability for its
intended use without interfering in any way with the integrity of the
material or its suitability for service.
BRICKS
Brick
• Introduction, Manufacturing,
characteristics, Classification and
uses
BRICK
Bricks are the most commonly
.
used
construction material.
Bricks are prepared by moulding clay in
rectangular blocks of uniform size and then
drying and burning these blocks. In order to
get a good quality brick, the brick earth
should contain the following constituents
Clay Products BRICK
• Clay is the most important raw material used
for making bricks.
• Purest clay consist mainly of Kaolinite
(2SiO2Al2O3.2H2O) with small quantity of
Quartz, mica, felspar, calcite, magnesite.
• Bulk Specific Gravity of clay bricks ranges from
1.6 – 2.5
Constituents of good brick earth:
• Silica
• Alumina
• Lime
• Iron oxide
• Magnesia
Silica
• Brick earth should contain about 50 to % of silica.
• It is responsible for preventing cracking, shrinking and
warping of raw bricks.
• It also affects the durability of bricks.
• If present in excess, then it destroys the cohesion between
particles and the brick becomes brittle.
Alumina
• o Good brick earth should contain about 20% to 30% of
alumina.
• o It is responsible for plasticity characteristic of earth, which is
important in moulding operation.
• o If present in excess, then the raw brick shrink and warp
during drying.
Alumina
• Good brick earth should contain about 20% to 30% of alumina.
• It is responsible for plasticity characteristic of earth, which is
important in moulding operation.
• If present in excess, then the raw brick shrink and warp during
drying.
Lime
• The percentage of lime should be in the range of 5% to 10% in
a good brick earth.
• It prevents shrinkage of bricks on drying.
• It causes silica in clay to melt on burning and thus helps to bind
it.
• Excess of lime causes the brick to melt and brick looses its
shape.
Iron oxide
• A good brick earth should contain about 5% to 7% of iron oxide.
• It gives red colour to the bricks.
• It improves impermeability and durability.
• It gives strength and hardness.
• If present in excess, then the colour of brick becomes dark blue
or blakish.
• o If the quantity of iron oxide is comparatively less, the brick
becomes yellowish in colour.
Magnesia
• Good brick earth should contain less a small quantity of
magnesia about1%)
• Magnesium in brick earth imparts yellow tint to the brick.
• It is responsible for reducing shrinkage
• Excess of magnesia leads to the decay of bricks.
Harmful Ingredients in Brick:
Below mentioned are some of the ingredients which are undesired
in brick earth.
Lime
• A small quantity of lime is required in brick earth. But if present
in excess, it causes the brick to melt and hence brick looses its
shape.
• If lime is present in the form of lumps, then it is converted into
quick lime after burning. This quick lime slakes and expands in
presence of moisture, causing splitting of bricks into pieces.
Iron pyrites
Alkalis
• These are exist in the brick earth in the form of soda and potash.
It acts as a flux in the kiln during burning and it causes bricks to
fuse, twist and warp. Because of this, bricks are melted and they
loose their shape.
• The alkalis remaining in bricks will absorb moisture from the
atmosphere, when bricks are used in masonry. With the passage of
time, the moisture gets evaporated leaving grey or white deposits
on the wall surface (known as efflorescence).
• This white patch affects the appearance of the building structure.
Pebbles
• Pebbles in brick earth create problem during mixing operation of
earth. It prevents uniform and through mixing of clay, which results
in weak and porous bricks
• Bricks containing pebbles will not break into shapes as per
Vegetation and Organic Matter
The presence of vegetation and organic matter
in brick earth assists in burning.
But if such matter is not completely burnt, the
bricks become porous.
This is due to the fact that the gasses will be
evolved during the burning of the
carbonaceous matter and it will result in the
formation of small pores.
Manufacturing of bricks
Manufacturing of bricks
In the process of manufacturing bricks, the
following distinct operations are involved.
• Preparation of clay
• Moulding
• Drying
• Burning
Preparation of clay
The clay for brick is prepared in the following
order.
• Unsoiling
• Digging
• Cleaning
• Weathering
• Blending
• Tempering
Preparation of clay
• A pug mill consists of a conical iron tub with cover at its top .It is fixed on a timber
base which is made by fixing two wooden planks at right angle to each other. The
bottom of tub is covered except for the hole to take out pugged earth. The diameter
of pug mill at bottom is about 800mm and that at top is about 1 m.The provision is
made in top cover to place clay inside pug mill .A vertical shaft with horizontal arms is
provided at center of iron tub.The small wedge-shaped knives of steel are fixed at
arms.The long arms are fixed at vertical shaft to attach a pair of bullocks .The ramp is
provided to collect the pugged clay .The height of pug mill is about 2m. Its depth
below ground is 600m to800mm lessen the rise of the barrow run and to throw out
the tempered clay conveniently.In the beginning, the hole for pugged clay is closed
and clay with water is placed in pug mill from the top. When vertical shaft is rotated
by a pair of bullock, the clay is thoroughly mixed up by the action of horizontal arms
and knives and homogeneous mass is formed.
• The rotation of vertical shaft can also be achieved by using steam, diesel or electrical
power.When clay has been sufficiently pugged, the hole at the bottom of the tub, is
opened out and pugged earth is taken out from the ramp by barrow i.e. a small cart
with wheels for next operation of moulding.The pug mill is then kept moving and
feeding of clay from top and taking out of pugged clay from bottom are done
simultaneously.If tempering is properly carried out, the good brick earth can then be
rolled without breaking in small threads of 3mm diameter.
Moulding
Moulding
• The clay which is prepared as above is then
sent for the text operation of moulding.
Following are two types of moulding:
• i. Hand Moulding
• The ground is first made level and fine sand is sprinkled over
it.The mould is dipped in water and placed over the ground.
• The lump of tempered clay is taken and is dashed is the
mould.The clay is pressed in the mould in such a way that it
fills all the corners of mould.
• The surplus clay is removed by wooden strike or framed with
wire. A strike is a piece of wood or metal with a sharp edge.
• It is to be dipped in water every time.The mould is then lifted
up and raw brick ids left on the ground.
• The mould is dipped in water and it is placed just near the
previous brick to prepare another brick.
• The process is repeated till the ground is covered with raw
bricks.
• The lower faces of ground moulded bricks are rough and it
is not possible to place frog on such bricks.
Frog
• Down draught kilns are more efficient because the heat is utilized
more by moving the hot gases in the larger area of the kiln. In up
draught kilns the hot gases are released after they rise up to
chimney entrance.
• Continuous Kilns:
• These kilns are called continuous because all the processes of
loading, unloading, cooling, heating, pre-heating take place
simultaneously.
• They are used when the bricks are demanded in larger scale and
in short time.
• Bricks burning are completed in one day, so it is a fast method of
Bull's Trench Kiln
• Bull's Trench Kiln:Bull's trench kiln consists of a rectangular, circular or
oval plan shape. They are constructed below the ground level by
excavating a trench of the required width for the given capacity of brick
manufacturing.This Trench is divided generally in 12 chambers so that 2
numbers of cycles of brick burning can take place at the same time for the
larger production of the bricks.
• Or it may happen that one cycle is carried out at one time in all the 12
chambers by using a single process in the 2-3 chambers at the same
time.The structure is under-ground so the heat is conserved to a large
extent so it is more efficient.
• Once fire is started it constantly travels from one chamber to the other
chamber, while other operations like loading, unloading, cooling, burning
and preheating taking place simultaneously.
• Such kilns are generally constructed to have a manufacturing capacity of
about 20,000 bricks per day. The drawback of this kiln is that there is not
a permanent roof, so it is not easy to manufacture the bricks in the
monsoon seasons.
Hoffman's Kiln
Hoffman's Kiln:The main difference between the Bull's trench kiln and the
Hoffman kilns are:
• 1. Hoffman's kiln is an over the ground structure while Bull's Trench Kiln
is an underground structure.
• 2.Hoffman's kiln have a permanent roof while Bull's trench Kiln do not
have so it former can be used in 12 months a year to manufacture bricks
but later is stopped in the monsoon season.
https://www.youtube.com/watch?v=8dgnGuzqxDA (HAND
MOULD
Tests on Bricks
Hardness test:
• In this test a scratch is made on brick surface
with a hard thing or finger nail. If that doesn’t
left any impression on brick then that is good
quality brick.
Size, shape and colour test
Color Test:
Good quality bricks are always uniform in color throughout its entire surface. Well burnt
bricks are always copper color Red cherry . In a lot, you can take the sample of the bricks and
see its color on all sides, if it is copper color and uniform it is quality one. See the copper
color of brick in image
Shape Test:
For Shape test, take at least 10 samples of bricks from a lot and check if their length, breadth
& width are uniform and it must not vary from brick-to-brick for the quality bricks.
Bricks are closely viewed to check if its edges are sharp and straight and uniform in shape.