Brick ManufactureCarlos Brown, Corey Henriquez, Michael

Berry, R.J. LavigneThe Knack

11/30/10

Basic Brick Properties Clay Bricks are made of Silica, Alumina, Lime,

Iron, Manganese, Sulfur, and Phosphates. They are poor conductors and are non combustible.

Young’s modulus = 1.5 x 106 psi – 5.0 x 106 psi Modulus of Rupture = 500 – 3800 psi Density = 125 pcf Common uses include building, facing, flooring,

and paving.

Manufacture Process Overview

Mining and Storage 3 Types of Clay are used to make Brick Surface Clays – sedimentary formations found on the

surface Shales – clays subject to high pressures until nearly

hardened into slate Fire Clays – mined at deeper levels than other clays Mined in open pits then transported to plant storage

areas

Manufacture Process Overview

Size Reduction Dry Pan Crushers- Breaks large chunks of

clay or shale Grinders- pulverizes the clay to a fine

consistency (Muller Wheels) Important to have clays dry when grinding

Screening

Passes through Vibrating Screen, Scalping Screen

Coarse material left goes back to grinder Hammer mill Large particles inhibit the durability of the

brick

Manufacture Process Overview

Forming Two steps in the forming process Tempering

Water is added to the clay in a pug mill Molding

Stiff Mud Soft Mud Dry-Press

Manufacture Process Overview

Drying The moisture content of the formed clay is

reduced, not eliminated, so that the brick will not explode during the firing process.

The clay is sent through a drying chamber for 24 to 48 hours at 100 to 400 deg F.

Heat and humidity must be regulated to avoid cracking in the brick

Manufacture Process Overview

Firing

Tunnel Kiln – Most Common, four stages

Final Drying and Dehydration: 300° F - 1800° F

Oxidation: 1000° F - 1800° F Vitrification: 1600° F - 2400° F Flashing: Varies depending on

desired color

Cooling and Processing Tunnel Kiln-10 hours Rate of Cooling has direct effect on color Dehacking

Unloading a kiln after cooling Bricks are sorted ,

graded, then packaged.

Works Cited Millberg, M. L. "How Brick Is Made - Material, Production

Process, Manufacture, Making, Used, Processing, Dimensions, Industry, Raw Materials, The

Manufacturing Process of Brick, Quality Control." How Products Are Made. How Products Are Made. Web. 29 Nov. 2010. <http://www.madehow.com/Volume-1/Brick.html>.

"Brick Manufacturing." Brickwork Design Guide by Glen-Gery Brick. Web. 29 Nov. 2010.

http://www.glengerybrick.com/>. "Manufacturing of Brick." Brick Industry Association - BIA. 2006.

Web. 29 Nov. 2010. <http://www.gobrick.com/>.