MAHARASHTRA STATE BOARD OF TECHNICAL

EDUCATION
GOVERNMENT POLYTECHNIC, JALGAON
(0018)
Program Name and Code : CE – R – 2I
Course Name and Code : CIVIL ENGINEERING
WORKSHOP & Practice
Academic Year : 2018-19
Semester : SECOND
A MICRO PROJECT
On
Manufacturing of bricks
Submitted on 2019 by the group of 5
students
Sr. Roll Enrolment
Name of student Seat No.
No. No. No.
1 1 HARSHA ATMARAM AGALE 1800180054
2 2 RUCHIT DAGADU ATTRADE 1800180033
3 3 ROHIT MADHUKAR 1800180027
BHAMARE
4 4 HARSHAL SHIVDAS BHOI 180018066
5 5 UMESH VISHVASRAO 1800180045
BORSE

Prof Nitin Rathod sir

Project Guide
1
 MAHARASHTRA STATE BOARD OF
TECHNICAL EDUCATION
Certificate

This is to certify that Master /Mos.

………………………………………………………….
Roll No. ……... of II Semester of Diploma in
……………………………………........
Of Institute, Government Polytechnic, Jalgaon (Code: 0018) has completed the
Micro Project satisfactorily in the Subject –Civil Engineering Workshop &
practice for the Academic Year 2018- 2019as prescribed in the curriculum.

Place: Jalgaon Enrolment no:

Date: …………………….. Exam Seat No:

Subject Teacher Head of the Department Principal

Seal of
Institution

2
 GOVTERNMENT POLYTECHNIC
JALGAON

-SUBMISSION-

I (Full Name)
…………………………………………………………………… Roll No. /Seat
No. …………………… as a student of …………. Seem/Year of the Programme
…………………………………………….. humbly submit that I have completed
from time to time the Micro-Project work as described in this report by my own
skills and study between the period from ……………………… to
…………………….. As per instructions/guidance of
And that following students were associated with me for this work, however,
quantum of my contribution has been approved by the Lecturer.
And that I have not copied the report on its any appreciable part from any
other literature in contravention of the academic ethics.

Date: ……/…../2019 Signature of Students

Evaluation Sheet for the Micro Project

3
Academic Year: 2018-19 Name of the Faculty: Prof Nitin Rathod
sir

Course: CEW Course code:

Semester: II
Title of the project: Manufacturing of bricks

Comments/suggestions about team work /leadership/inter-personal

communication (if any)
………………………………………………………………………………………
………
Marks out of Marks out of
6 for 4for
Roll Student Name performance performance in Total out
No in group oral/ of 10
activity presentation
(D5 Col.8) (D5 Col.9)

4
 INDEX

SR.NO. CONTENT PAGE NO.

1.
Manufacturing of Burnt Clay 8
Bricks

2. Fly ash bricks manufacturing process 16

5
 WEEKLY PROGRESS REPORT

SR.NO. WEEK ACTIVITY PERFORMED SIGN OF GUIDE

DATE
1 Discussion and finalization
of topic

2 Preparation and submission

of Abstract
3
First Literature Review
Week
4 Collection of Data

5 Collection of Data

6 Discussion and outline of

Content
Second
7 Week Formulation of Content

8 Editing and proof Reading of

Content
9 Compilation of Report And
Presentation
10 Seminar

11
Third Viva voce
Week
12 Final submission of Micro
Project

Sign of the student Sign of the faculty

6
References:
Wikipedia
Google

7
 1. Manufacturing of Burnt Clay Bricks
The manufacture of bricks consists of the following operations:
(I) Preparation of day, (II) Moulding, (III) Drying, and (IV) Burning.

(i) Preparation of the clay

 The preparation of the day is done manually or by mechanical excavators it consists of
the following steps: (a) Unsoiling, (b) Digging, (c) Stone picking, (d) Addition of sand
and chalk, (e) Weathering, (f) Tempering.

 Unsoiling consists in removing vegetation, organic matter, kankar particles etc.

 Digging is the process of excavation of the clay. Clay is dug manually or by machine and
heaped up to a certain height above the ground.
 Stone picking is done normally, but if in excess, the clay is washed and strained.

 Addition of chalk and sand is done at this stage for preparation of better quality bricks, if
required.

 Weathering consists of leaving the heaps of the clay exposed to the action of atmospheric
agencies and bacteria for a period of at least a 'month. Weathering has important effect on
the plasticity and strength of the clay.

 Tampering is the process of kneading the clay into a homogeneous mass with uniform
consistency with plasticity suitable for moulding process.

 Kneading is done by men or cattle, who tread over the clay, which is first turned over,
two or three times, then kneaded and battered by spades and shovels.

 When ‘the‘demand for bricks is sufficiently great, the clay is tempered by passing the
day through a pug, mile. The tempered soil coming out of the plug mill is collected for
moulding operations.

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 The pug mill has a circular iron tub of 1 m to 2 m height, having 1 diameter at top and
about 0.75 m diameter at bottom. A vertical knife is attached to each arm and is in the
centre of the tub.

 The shaft is revolved by along horizontal arm run by bullocks. From the top, roughly
mixed clay and water are fed into the mill.

 Because of the revolving shaft, knives function, break all lumps and mix the clay
homogeneously. The pugged clay is taken out from the opening at the bottom of the iron
tub.

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(ii) Moulding:

 Moulding is the process of giving desired shape to the tempered clay by hand or machine.
 Hand moulding is resorted in case of soft clay and is done on the ground or on the table.

 In hand moulding, a mould of wood or iron is used. The mould is either dipped in water
or sand to avoid the adhesion of clay in the mould. Clay is shaped, introduced in the
mould firmly, the mould is lifted, given a slight jerk and inverted to release the moulded
brick.

 In table moulding, the moulder uses a table. The moulded bricks were laid on a pallet
board in case of table moulding or on dry level surface of the ground in case of ground
moulding.
 Clay bricks are also formed on brick-pressing machines. Machine moulding is
advantageous when larger number of bricks are required to be made in short time. Where
the clay IS hard machine moulding is more convenient
 The bricks are cheaper and better in quality.

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(iii) Drying:
 Drying is the process wherein the object is to evaporate all superfluous moisture without
damaging the brick, make the bricks hard enough to be handled and to impart the
required strength to withstand pressure during operations in kilns or clamps used in
burning.
 Bricks are dried by: (a). natural drying or hack drying and (b) artificial drying.

(a) Natural drying:

 Wet bricks are arranged in rows on their edges on a raised ground called ”stacks",
keeping space in between for circulation of air and kept as such in open air for one or
two weeks. .

(b) Artificial drying:

 It is .used when large quantities of bricks are required in shortest time.

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  The bricks are dried (I) in a special furnace built for this purpose, (ii) by hot flue gases
from the cooling chamber and (iii) by waste steam engines of a driving machinery.

(iv) Burning of Bricks:

 It Is the process carried out with the following purposes: (I) to drive out the water from
the clay and thus to make it lose its plasticity and to convert it into a homogeneous mass,
(ii) to impart hardness and strength to resist compression, (iii) to increase the density in
order to decrease water absorption capacity, (iv) to manufacture the brick in such a way
that it can resist the disintegrating effects of atmospheric agencies

Process of Burning:
The dry bricks or so called green bricks are burnt either in (a) a clamp or (b) a kiln, namely
Hoffman's kiln or Bull's trench kiln.

(a) CLAMPS:
 In clamp, the bricks and fuel are placed in alternate layers for burning bricks in the open
air. There is no enclosing wall as is present in the Kilns.
 The clamps burn either wood or coal as a fuel. Clamps using coal produce better quality
bricks and are economical than clamps using wood as a fuel.
Advantages of Clamp Burning:
1. It is economical.
2. It is easily manageable by common brick burners.
3. The bricks are tougher than those produced in Kiln cooling as well. \

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Disadvantages of Clamp Burning:
1. It is a slow process.
2. Fire cannot be regulated and hence there is less control on temperature.
3. The products in the form of bricks are not uniform, but a few are distorted and cracked.
4. Wastage is more. '
5. Quality of bricks produced is poor than that from Kiln burning.

(b) KILNS:
 In kiln, the bricks are stacked without any fuel and burnt. From the fire places or flues.
The places are _ arranged below the stack.’ '

 Fire is lighted below the stack and kept continuous by supply fuel till the bricks are burnt.
The kiln has a permanent enclosing wall inside which the bricks are placed over flues. ’
 The kilns used are (a) Hoffman kiln, and (b) Bull’s trench kiln.
 By considering 12 chambers. Chamber numbers 3 to 12 are kept full, chamber No. 1 is
kept in the process of loading and chamber
 No. 2 is in the process of emptying. The flue in timber No. 12 is opened while the
remaining flues are closed. The draught is thus made to
 Pass through all the loaded chambers. Chambers 3, 4, S and 6 are made to burn, while
chambers 7 and
 8 are in the stage of drying. The openings in the bottom of the partition between No.12
and No. 1 are covered so that the draught
 Does not pass through No. 1. When No. 1 chamber is loaded, No. 2 is kept empty and the
openings at the bottom of the
 Between No. 1 and No. 2 are kept at No. 1 is opened and that of No... 12 is “closed.
Draught removes dampers between Nos. 12 and 1.
 The cycle of operation is repeated and the process is kept continuous till required.

Bull's Trench Kiln

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 The kiln 15 made me a trench dug below the ground surface m rectangular.
 The length is dependent on the number of bricks to be manufactured. The oval type is to
be Suitable when space available is less. Circular and rectangular shapes ensure uniform
burning
 They are stacked With spaces in between them and flues are formed at the bottom The
flues are provided with holes, through which the fuel is fed to the flues during firing
 The Kiln Is loaded in separate sections over which two draught chimneys are placed the
section is loaded with bricks, covered with earth ‘or ashes to prevent heat from escaping.
 When one section is being burnt the hot gases pass into next section and heat the backs
there before they pass through the chimneys.
 When one section is being burnt and the fire advances to the next, all flue holes are shut
and the section is allowed to cool slowly.
 During this time the firing advances through different sections from one Sled Thus the
section that is

 Burnt first cools enough and to unloaded and reloaded with dried bricks, which are, In
turn, warmed up by hot gases with previous section and then burnt by incoming fire
circulating the kind. The kiln, thus functions with a continuity.
 It is cheapest since more than 500,000 bricks can be burnt though it cannot work in rainy
season.

Bull's Trench Kiln

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 \

2. Fly ash bricks manufacturing process

Process of manufacture of fly ash bricks

Fly Ash-Sand-Lime Bricks: (As per CBRI)]

Brick Composition:

Fly Ash 40 - 50%

Sand 50 - 40%

Lime 10%

 Lime is finely ground in a ball mill/pulveriser. Fly ash, finely ground quick line and sand
in requisite proportions are fed in double roll paddle mixer or U-shaft mixer (Double
shaft mixer) by means of a feeder.
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 Then 4% water is added and intimate mixing is done. The mixing proportion (as per
Brick composition given above) is generally 40-50% Fly Ash, 50-40% Sand 10% lime
and 4% water

 Fly ash reacts with lime in the presence of moisture to form calcium silicate hydrate
which is the binder material.

 After this the mixture is discharged and sent to manual presses for moulding; which is a
moulding machine developed by C.B.R.I.

 C-Brick Machine has 4=Brick Block at a time with capacity 2500 Bricks/day (Cost of
m/c = Rest. 40,000).

 The raw mix is moulded in the moulding press/machine, pressed under a pressure into
bricks. The bricks are then withdrawn from the moulding machine and they are air dried
under the sun and kept for 1 day.

 The bricks are conveyed either by placing on platform trolleys or by conveyors to curing
chamber/autoclave in which curing is done by steam at normal pressure and cured for 6 -
8 hours (Steam Curing).

 Trolleys with ready bricks to the storage yard, where they are unloaded by overhead
traveling crane and a grip tongue.
 24 hours after curing, the bricks are ready for use. The final products are sorted out and
inspected for quality and stacked in the go-down or yard or loaded on trucks for
marketing for use in construction.

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 The whole processes can be divided into following unit operations:
1. Grinding & Mixing :

Methods of grinding and mixing depend upon the composition of the fly ash

And the layout of the plant. To get a high strength calcium silicate materials, it

is advantageous to mix and grind lime and sand for a greater period and then

mix the remaining quantity of fly ash and mix for a further short period so that

only a portion of the ingredients receive such Grinding. Mixing and

proportioning may be done either by batch or continuous Process.

Generally batch methods are preferred for the primary stage to achieve a good control on the
operation.
Raw materials, water stains and other chemicals are properly mixed in a double - shaft or U-
shaped mixer or counter-current mixer (costlier) till the semi-dry mix is uniform and ready for
pressing.
Trolleys: Each trolley carries about 750 to 1500 bricks and an autoclave may hold up to 20 such
trolleys or more depending upon its length.
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2. Pressing :

In general, after the mixing and grinding, the material is placed in an instant stripping
mould with a high powered external vibrator of 180 112 frequency. During compaction the top
surface is pressed at a 300 kg/cm2 on each brick. A wooden plate is then set on the top surface
and the mould is turned upside down. Finally the mould is stripped by lifting it up. It is necessary
to use high pressure moulding because the mixers are non-plastic in nature. The press required
for this purpose has to be sufficiently robust to withstand the high chemical strains and wear and
tear to which it is to be subjected.

3. Removal & Stacking for Curing/Autoclaving :

The pressed bricks are removed from the press either manually or by an automatic press
off loading and brick stacking machine, designed to work in conjunction with the brick making
press, and among on trolleys. Each trolley carries about 750 to 1500 bricks and an autoclave
may hold up to 20 such trolleys or more depending upon its length.
Autoclaving:

Autoclave, a long horizontal cylinder, with one of the end usually closed and the other
door is removable to allow the trolleys to more in and out on rails. After that trolleys have been
placed in the autoclaves, the doors are tightly closed and steam at normal pressure is fed inside
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and curing is done for 6-8 hours. The steam in autoclave is allowed to blow off slowly through a
release valve and the contents are allowed to cool. The chamber is then opened and the trolleys
are drawn and the cooled bricks are stored in the yard. Thus autoclave is available immediately
for recharging.

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