bricks formation
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Transcript of bricks formation
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Manufacturing Bricks
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Bricks
• A brick is a block, or a single unit of a ceramic material used in masonry construction.
• Bricks are typically produced in common or standard sizes in bulk quantities.
• It is one of the longest lasting and strongest building materials used throughout history.
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HISTORICAL DEVELOPMENTS IN MASONRY
• It is the simplest of all the building techniques.
Sun-dried bricks - With the availability of fire became burnt bricks
Invention of kilns made mass production of bricks easy
Limestone turned into lime mortar replaced mud as mortar
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Masonry History
Rich History Through the mid-1800s
– Primary Building Materials Late 1800s
– New Products Developed– Ended Masonry’s Dominance
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Brick Masonry - Uniqueness
Fire Resistance
Size
Durability
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MANUFACTURE OF BRICKS FROM CLAY
• Constituents: Brick clays are produced by blending together various clays (surface clays, shales, and fire clays) to produce the desired chemical composition and physical properties.
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STEPS FOR BRICK FORMATION
• Clay Preparation• Molding• Drying• Firing
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Clay Preparation
• Clay preparation methods may have to accommodate the physical characteristics of the raw material.
• Special provision may have to be made to deal with certain impurities.
• Preparation consists of transforming the clay rock into plastic moldable material.
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Molding
• Molding utilizes a drier clay mix, formed into a wedge and thrown into a mold.
• A bow cutter will be used to smooth the top of the brick, and the form will can be released because of a hinged bottom.
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Drying
• Water was added during clay preparation to increase workability of the mixture, but in drying it is removed for several reasons.
• First, there will be less cracking in fired bricks with less water content.
• Second, additional fuel is needed, beyond what is used for firing, to dry the bricks in the kiln.
• Proper drying of bricks will involved rotating the bricks for different exposures to ensure even drying rates.
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Firing
• Bricks are burnt either in a periodic kiln or a continuous tunnel kiln.
• Stages of burning: Water-smoking and dehydration (drives off the remaining water from clay at 40o to 150o C).
• Temperature of furnace rises to 1000o to 1300o C - Clay transformed to a ceramic material -
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Brick Masonry - Sizes and Shapes
No standard size Normal coursing - 3 bricks = 8” Larger sizes Custom Shapes & Colors
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No single standard size available - Size varies Modular Brick: 3 1/2” x 7 1/2” x 2 1/4” (Actual size) Standard Brick : 3 1/2” x 8” x 2 1/4” Engineer Modular : 3 1/2” x 7 1/2” x 2 3/4” Engineer Standard : 3 1/2” x 8” x 2 3/4” Close Modular : 3 1/2” x 7 1/2” x 3 1/4” Roman : 3 1/2” x 11 1/2” x 1 5/8” Norman : 3 1/2” x 11 1/2” x 1 5/8” Brick may be solid, cored, hollow or frogged - This allows even drying of bricks Custom-shaped bricks are often required for building for providing special
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SIZES, GRADES AND TYPES OF BRICKS
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Brick Bonds Structural Bonds Cavity (Veneer) Walls
– Running bond– Stacked bond
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