BRICK

BRICK

Brick is nothing but baked clay.

Brick is an artificial stone made by

forming clay into rectangular blocks
which are hardened, either by
burning in a kiln or sometimes by
sun-drying.

BRICK
CHEMICAL COMPOSITION
In order to get a good quality brick,
the brick earth should contain the
following constituents.
Silica:
• Brick earth should contain about 50% of silica.
• Silica exists in all clays in a state of chemical combination and some times
in a free state when it is called sand.
• The presence of sand prevents cracking, shrinkage and warping.
• The higher proportion of sand make the brick more uniform in texture.
However, too much sand makes the brick weak.
Alumina (Aluminum Oxide):
• Good brick earth should contain about 20% to 30% of alumina.
• It is responsible for plasticity characteristic of earth, which is important in
molding operation.
• If present in excess, then the raw brick shrink and warp during drying.

Iron Oxide:
• Silica 50% • A good brick earth should contain about 5% to 7% of iron oxide.
• Alumina 20% -30% • It gives red color to the bricks.
• Lime 5% - 10% • It improves impermeability and durability.
• Iron oxide 5% - 7% • It gives strength and hardness.
• Magnesia 1% • If present in excess, then the color of brick becomes dark blue or blackish.
• Organic matters 1% • If the quantity of iron oxide is comparatively less, the brick becomes
yellowish in color.
 BRICK
Magnesia (Magnesium Oxide):
• Good brick earth should contain less a small quantity of magnesia about 1%.
• Magnesium in brick earth imparts yellow tint to the brick.
• It is responsible for reducing shrinkage.
CHEMICAL COMPOSITION • Excess of magnesia leads to the decay of bricks.

In order to get a good quality brick, Lime:

the brick earth should contain the • The percentage of lime should be in the range of 5% to 10% in a good brick
following constituents. earth.
• It prevents shrinkage of bricks on drying.
• It causes silica in clay to melt on burning and thus helps to bind it.
• Silica 50% • Excess of lime causes the brick to melt and brick looses its shape.
• Alumina 20% -30%
• Lime 5% - 10% Organic Matter:
• Iron oxide 5% - 7% • A small quantity of organic matter will assist burning bricks.
• Excess is bad, because if it is not completely burnt, the bricks will be porous.
• Magnesia 1%
• Organic matters 1%
 BRICK
HARMFUL INGREDIENTS
These are some of the ingredients
which are undesired in brick earth.
Iron pyrites:
• The presence of iron pyrites in brick earth causes the brick to get crystallized
and disintegrated during burning
• Pyrites decolorize the bricks.
Pebbles:
• Pebbles prevents uniform and thorough mixing of clay, which results in weak
and porous bricks
• Bricks containing pebbles will not break into shapes as per requirements.

Vegetation and Organic Matter:

• Iron Pyrites • The presence of vegetation and organic matter in brick earth assists in burning.
• Pebbles But if such matter is not completely burnt, the bricks become porous. This is
• Vegetation and Organic due to the fact that the gases will be evolved during the burning of the
matter carbonaceous matter and it will result in the formation of small pores.
• Alkalis

BRICK
HARMFUL INGREDIENTS
These are some of the ingredients
which are undesired in brick earth.
Alkalis:
• Exists 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.

• Iron Pyrites
• Pebbles
• Vegetation and Organic
matter
• Alkalis
 1. Bricks should be uniform in color, size and shape.
BRICK
The standard dimension is 240 x 115 x 70mm. (9.5 x 4.5 x 2.75 inches)

1. They should be sound and compact.

2. They should be free from cracks and other flaws such as air bubbles, stone
nodules, etc. with sharp and square edges.

3. They should not absorb more than about 1/5 of their own weight of water
when immersed in water for 24 hours (15 to 20% of dry weight)
CHARECTERISTICS OF GOOD BRICKS
4. The average compressive strength of bricks should be in the range of 2500 psi.

5. The percentage of soluble salts (Sulphates of Calcium, Magnesium, Sodium

and Potassium) should not exceed 2.5% in burnt bricks. Because the presence
of excess soluble salts causes efflorescence.

6. They should be neither over-burnt nor under-burnt.

 BRICK

8. The weight should be generally 2.7Kg (6 lb.) per brick and the unit weight
should be generally 2000 Kg/m3 (125 lbs/cft).

9. They should have low thermal conductivity as it is desirable that the

buildings made of them should be cool in summer and warm in winter.

CHARECTERISTICS OF GOOD BRICKS 10. They should be non-inflammable and incombustible.

11. Bricks should NOT change in volume when wet.

12. They should give clear ringing or metallic sound when struck by another
brick or hammer.
 1 2 3
Take two bricks and
BRICK Take a brick and try form a T as shown in Take a brick and
to make a mark on the following figure strike it with a
its surface with nail. and drop from a hammer or
height of 1.2m (4 ft.) another brick.
If you can do this, it to I .5m (5 ft.) on a
more or less solid If it gives a clear
is not a good brick.
surface.
ringing or metallic
If not, it is If they remain sound it is a good
FIELD TESTING sufficiently hard and unbroken, they are brick.
OF BRICKS compact. good bricks.

If they break, they are

not good bricks.
Brick Terminology
BRICK TERMINOLOGY BED
The lower 19x9 cm surface of a brick when laid flat.

FROG
A perforation or hole on the longer face of a brick made with
the object of forming an indentation for the mortar. This hollow
depression also reduces the weight and makes it easier to
handle. The depth of the frog is usually between 10 to 20 mm.

Frogged bricks should lay with the frog upward and fill up with
mortar. The reason is to obtain higher strength, stability, and
sound insulation.

HEADER SIDE
The shorter side or end face of a piece of brick that is exposed.
(9X9 cm side).

STRETCHER SIDE
The longer narrow side or face of a piece of brick that is
exposed. (19x9 cm)
 BRICK TERMINOLOGY

BAT
1 The portion of brick that is cut across the width.

These are of different sizes and shapes, eg., ½ bat, ¾ bat and beveled bat.

1. Half Bat
When the length of a bat is equal to half of the length of the original brick
2
2. Three Quarter Bat
When the length of the bat is equal to three-quarters of the length of the
original brick.

3. Beveled Bat
3 When a bat has its width beveled.
 BRICK TERMINOLOGY CLOSER
The portion of the brick cut lengthwise in such a manner that its one long
1 2 face remains uncut. Usually used to end a brick course or building beautiful
corners.
The types are:
1. Solid Brick
Typical brick with no cavities or void spaces.

4 2. Queen Closer (Half)

3
The piece of brick taken by cutting a brick lengthwise into two parts.
3. Queen Closer (Quarter)
When the queen closer is cut in half, then it is called a queen closer quarter.
4. Mitered Closer
These are bricks where one end is cut at an angle from 45 to 60 degrees.

5 6 5. King Closer
Brick that is obtained by cutting from the center of one header to the center
of the stretcher on the other side. They are used to finish corners.
6. Beveled Closer
Similar to king closer but with the difference that the whole length of the
brick is beveled.
 BRICK TERMINOLOGY BULL NOSE
A bull nose brick is a type of brick that has one or some of its corners rounded
1 2 off. They are typically used to build soft and attractive curved edges to steps,
ledges, or in capping walls. There are many types of bull nose bricks:

1 . Single Bull Nose

One corner of the brick is rounded off.

3 4 2 . Double Bull Nose

Two corners of the brick are rounded off.

3 . Cow Nose
It has both corners of the brick rounded off at one of the ends.

4 . Single Bull Nose Header

6 Top header side corner of the brick is rounded off.
5
5 . Single Bull Nose Stretcher
Top stretcher side corner of the brick is rounded off.

6 . Bull Nose Double Stretcher

Both top stretcher side corners of the brick are rounded off
BRICK TERMINOLOGY

DOUBLE BULL NOSE

3 DOUBLE BULL NOSE

COW NOSE
BRICK TERMINOLOGY WAYS TO LAY A BRICK
There are six ways:

1. Stretcher
This is how you typically lay a brick, with the stretcher side
being the most visible side.

2. Header
Head side is the most visible face of the brick.

STRETCHER

HEADER
 WAYS TO LAY A BRICK
BRICK TERMINOLOGY
There are six ways:

3. Rowlock Stretcher
When the thin stretcher sides are on bottom and top and
head faces on the sides.

4. Rowlock
The head is visible, and the long narrow sides are on
bottom and top.
ROWLOCK STRETCHER

R O W LO C K
 WAYS TO LAY A BRICK
BRICK TERMINOLOGY There are six ways:

5. Soldier
The stretcher side is visible and the heads are at the bottom
and top. It is usually used for decoration.

6. Sailor
The heads are on top and bottom, and the stretcher faces
are on the side. Mostly used for decoration.

SOLDIER

SAILOR
 BRICK TERMINOLOGY COURSE
A continuous horizontal layer of similar bricks or stones that are
bonded with mortar in a masonry structure and is one unit high.
TYPES OF COURSES
1. STRETCHER COURSE
A course of bricks or stones that lie with its longest side
parallel to the face of the work. The course of brickwork in
1 which all the bricks are laid as stretchers is known as
stretcher course.

2. HEADER COURSE
The course of brickwork in which all the bricks are laid as
2 headers is referred to as header course. Three-quarter bats
are used for the corners. A header course requires twice as
many bricks as a stretcher course making it more time
consuming and expensive to build.

3. SOLDIER COURSE
3 Bricks that are set with the narrow side exposed are called
soldiers. Bricks laid vertically with its long narrow sides
presented (Soldiers) in a row is called a soldier course.
Usually used to add visual interest to a masonry structure.
Classification of Bricks
 CLASSIFICATION OF BRICKS

BRICKS BRICK
COMPOSITION M A B U FA C T U R I N G SHAPE
QUALITY USE PROCESS

First Class Facing Bricks Common Burnt

Bricks Clay Bricks Solid Bricks
Sun Dried
High Bricks
Sand Lime
Temperature
Bricks
Resisting Bricks Frogged Bricks
Second Class
Engineering
Bricks
Acid Resisting Bricks
Bricks Fired Cored Bricks
Concrete Bricks Bricks
Third Class
Bricks Light Weight Fly Ash Clay Hollow Bricks
Clay Bricks Bricks
 FIRST CLASS BRICKS
The bricks which are well burnt and are of uniform size, shape and color
CLASSIFICATION OF BRICKS are known as first class bricks.

PROPERTIES

Based on
• They should be thoroughly and evenly burnt.
Quality of Bricks • They should be well shaped with even surfaces.
• They should be free from cracks or flaws, chips, stones of any kind.
• They should ring clearly when struck with a hammer or another brick.
First Class
Bricks
• Regular surface, parallel sides and sharp edges.
• Uniform red or brownish colored.
• They are made from good earth and free from pebbles, lime lumps,
organic matter and sodium salt.
Second Class • It should be 19x9x9cm or 9.5x4.5x2.75 inches
Bricks
• High crushing strength, not less than 10.7 N/mm2
• Machine molded
• Efflorescence- NIL
Third Class • Water absorption less than 15%
Bricks
• It should not break from when dropped from a height of 1m.

USES
They are used for the exterior wall brick works, short columns and
arches.
CLASSIFICATION OF BRICKS
SECOND CLASS BRICKS
The bricks that possess the hardness and color of first class
bricks but are slightly irregular in shape, size or rough on the
Based on surface are known as Second Class Bricks.
Quality of Bricks
PROPERTIES
First Class
• Slightly uneven faces, texture and edges are not crisp.
Bricks • Uniform colored but may be slightly irregular in shape.
• High crushing strength, not less than 7 N/mm2
• Hand molded
• Efflorescence- little
Second Class
Bricks • Water absorption less than 20%

USES
Third Class
Bricks They are used for internal and compound walls (commonly
used at places where brick work is to be provided with a coat of
plaster).
CLASSIFICATION OF BRICKS THIRD CLASS BRICKS
The bricks which are not sufficiently well-burnt and do
not have uniform shape and size are known as third
class bricks.
Based on
Quality of Bricks PROPERTIES
• Under burnt, Soft and non uniform texture
First Class
• Yellowish in color, non uniform
Bricks • May be distorted with blunt edges
• High crushing strength, not less than 3.5N/mm2
• Hand molded
Second Class
• Efflorescence- LARGE
Bricks • Water absorption less than 25%
• They emit a dull sound when struck against each
other.
Third Class
Bricks USES
• Temporary building construction, scaffolding
• Used for flooring, paving and small brick foundations
 C O M M O N B U R N T C L AY B R I C K S
CLASSIFICATION OF BRICKS
• Formed by pressing wet clay in molds, then drying and firing them in a
kiln.
• Common burnt clay bricks are used in general work with no special
attractive appearances.
Based on • When these bricks are used in walls, they require plastering or rendering.
COMPOSITION • Uses for burnt clay bricks include: Masonry walls, Foundations, Columns

SAND LIME BRICKS

Common Burnt • Sand lime bricks are made by mixing sand, fly ash and lime followed by a
Clay Bricks chemical process during wet mixing. The mix is then molded under
pressure forming the brick.
Sand Lime • These bricks can offer advantages over clay bricks such as: their color
Bricks appearance is grey instead of the regular reddish color.
• Their shape is uniform and presents a smoother finish that doesn’t require
Engineering plastering.
Bricks • These bricks offer excellent strength as a load-bearing member.
• When pigments are added, the bricks can be used for ornamental
Concrete Bricks purposes.
• Less mortar is required during construction.
• Edges are straight and precise, making construction easier.
Fly Ash Clay
• Bricks do not effloresce salts and minerals.
Bricks
• The uses for sand lime bricks include:
-Structural foundations and walls
-Exposed brick walls and pillars
-Ornamental uses (when pigments are added)
CLASSIFICATION OF BRICKS ENGINEERING BRICKS
• Manufactured at extremely high temperatures, forming a dense and
strong brick, allowing the brick to limit strength and water absorption.
• Offer excellent load bearing capacity, damp-proof characteristics and
chemical resisting properties.
Based on
COMPOSITION

CONCRETE BRICKS
Common Burnt • Made from solid concrete.
Clay Bricks • Usually placed in facades, fences, and provide an excellent aesthetic
presence.
Sand Lime • Can be manufactured to provide different colors as pigmented during its
Bricks production.
• Common uses for concrete bricks include: Fences, Facades.
Engineering
Bricks

Concrete Bricks F LY A S H C L AY B R I C K S
• Manufactured with clay and fly ash, at about 1,000 degrees C.
Fly Ash Clay • Has the advantage of being lighter in weight than clay or concrete brick.
Bricks • Typical uses for fly ash clay brick include: Structural walls, Foundations,
Pillars.
CLASSIFICATION OF BRICKS

SOLID BRICK
• A solid masonry unit with no cavities, holes or indentations.
Based on • A solid brick has a maximum void area of 25%.
SHAPE

FROGGED BRICK
Solid Bricks A masonry unit with a cavity on one of its bed faces with no more
than 20% of its volume hollow.

Frogged Bricks
CORED BRICK
• A masonry unit that has holes or cores in its cross-sectional area
Cored Bricks with no more than 20% of its volume hollow.
• These cores reduce the weight of the brick and allow for faster
firing of the brick.
Hollow Bricks

HOLLOW BRICK
• A masonry unit that has more than 25% of its volume hollow.
• They can have up to 60% of its volume empty.
Brick Bonding
 BRICK BONDING

The method of arranging bricks in a pattern so that the individual units are tied together.
Bonding is crucial to eliminate consecutive vertical joints as this will create a weak brick
structure. It is also referred as the adhesion between mortar and brick or stone units and
when attaching several types of masonry walls by overlapping masonry units.
 STRETCHER BOND

HEADER BOND

ENGLISH BOND

FLEMISH BOND

TYPES OF BONDING STACK BOND

ENGLISH GARDEN
WALL BOND

FLEMISH GARDEN
WALL BOND

ENGLISH CROSS
BOND

DUTCH BOND
TYPES OF BONDING
STRETCHING/STRETCHERBOND
• Course of bricks that are all laid as stretchers, i.e., with their lengths in the
direction of the length of the wall.
• It is also called a running bond.
• This is used for partition walls which are only ½ brick thick (5”).
• In thick walls, this arrangement is impracticable because there is no bonding
across the wall.
• If used as a structural bond it needs the proper reinforcement.

HEADING/HEADERBOND
• Course of bricks that are all laid as headers on the faces.
• A three-quarter bat is used in every other course as quoins and to properly
overlap.
• This is used for walls which are one brick thick and is especially used for
curved brickwork.
• This bond does not possess the strength to transmit pressure in the direction
of the length of the wall and, consequently is not employed for walling.
BRICK: Brick Bonds:
Stretcher Bond

• Only stretchers are used

• Half brick (5”) thick walls only
 BRICK: Brick Bonds:
Heading Bond

• All brick courses are laid as headers

• Three-quarter bats are used at the corners to get ¼ brick overlap

Header

Three Quarter Bat

TYPES OF BONDING
ENGLISH BOND

• Alternate courses of stretchers and headers.

• Considered the strongest bond in brickwork.
• Used for load bearing walls.
• The second and the previous to last is a Queen closer (half)
for all the header courses.
• A header course should NEVER start with a queen closer as it
would get displaced.
• Every alternate header comes centrally over the joint
between the two stretchers in the course below.
• There is no continuous vertical joint.
• The number of vertical joints in the header course is twice
the number of joints in the stretcher course. Hence the joints in
the header course should be made thinner than those in the
stretcher course.
BRICK: Brick Bonds:
English Bond

• Alternates courses of headers and stretchers

• A heading course should never start with a queen closure as it is liable to get displaced easily
• Stretcher course should have ¼ th of a brick’s length over the headers
Stretcher Course

Header Course
One brick
thickness
(10”)

Queen Closure
TYPES OF BONDING

FLEMISH BOND

• An alternate course of bricks that are composed of one header to one

stretcher.
• The headers and stretchers appear in the same course alternately on
the front and the back faces.
• Each course starting with a stretcher will end with a stretcher.
• The courses starting with a header will end with a header as well.
• A header in any course is in the center of a stretcher in the course above
or below it.
• Queen Closers are inserted in alternate course next to the quoin header
for breaking the vertical joints in successive courses.
• This bond uses more mortar as it contains larger number of joints.
• Many times, the stretcher and headers will be of different color to
create patterns.
BRICK: Brick Bonds:
Flemish Bond

• Each course consists of headers and stretchers

• The headers of each course are placed over the center of the stretchers of the immediate layers
above and below
Stretcher

Header
One brick
thickness
(10”)

Queen Closure
TYPES OF BONDING

STACK BOND

• In a stack bond, all the bricks are plainly loaded on top of each
other and held with mortar where all bonds are perfectly aligned.
• Because of its weak masonry structure and less strength.
• Stack bonds are perfect for decorative purposes.
• This bond is a non-structural bond, hence not suitable for walls
which require to transfer loads.
 TYPES OF BONDING

This bond permits better alignment

and as such it is used for walls curved
on plan.

A wall having continuous vertical joints

does not act as a homogeneous mass
to distribute the superimposed load.

Defective arrangement of bricks

reduces the strength and durability of
the structure.
 TYPES OF BONDING

E N G L I S H G A R D E N WA L L
BOND

• This consists of one course of

headers after three or five courses
of stretchers.

• A queen closer is placed next to

the quoin header in each header
course.

• The middle course of stretchers is

started with a header to give the
necessary lapping.
 TYPES OF BONDING

F L E M I S H G A R D E N WA L L
BOND

• This comprises of one header after

three or five stretchers in each
course.

• A ¾ bat is introduced next to the

quoin header in every alternate
course and a header is placed over
the middle of each stretcher.
 TYPES OF BONDING

ENGLISH CROSS BOND

• This consists of alternate courses

of headers and stretchers where
every alternate stretcher course
has a header introduced next to
the quoin stretcher.

• This is used for walls where

strength as well as beauty is
required.
 TYPES OF BONDING

DUTCH BOND

• This bond is built up with ¾ and ½

brick closers along with the regular
header and stretchers.

• This is slightly stronger at the

junction than the common type of
bonds used.
 TYPES OF BONDING

PAVINGBRICKBONDS
Brick paving are entirely supported by the
underlying surface. Few of the most common
paving brick bonds are:
R u n n i n g b o n d – Same pattern as the wall
brick, but these can be done parallel,
perpendicular , or diagonal to the length of a path
or patio.

H e r r i n g b o n e b o n d –A very simple zig-zag

pattern where each brick is perpendicular to its
neighbors.

B a s k e t w e a v e B o n d – A square pattern
with bricks placed side-by-side in pairs, and each
pair is perpendicular to its neighbors. This is an
easy pattern for areas that are rectangular or
square in shape.

S t a c k e d B o n d – Also known as Jack-on-Jack

paving. This is a square grid of even rows with no
staggering between courses.

Brick bonds for paving can be more decorative

and flexible in design.
 WORKDETAIL M AT E R I A L S
ESTIMATION
FOR BRICKS
100 cft brickwork 1100 bricks

100 cft khoa (brick chips) 850 bricks

- One thousand bricks weigh about
3.5 ton.
100 sft 5 inches brick work 480 bricks
- The standard dimension is
240x115x70mm. (9.5 x 4.5 x 2.75 inches).
100sft brick flat soling in
300 bricks
- With mortar it becomes foundation and floor
10 x 5 x 3 inches (single brick)

100sft Herring Bone Bond

soling in foundation and 500 bricks
floor
Manufacturing of Bricks
 1 2
MANUFACTURING OF BRICKS

SELECTION PS R
SELECTIONOF E LE EP CA TRIAOTNI O
ONF
OF BRICK-
BRICK-CLAY B ROI CF KC-LCALYA Y
CLAY

In the process of manufacturing

bricks, the following distinct
operations are involved.
3 4 5

S EMLOE U
C TL IDOI N
NGOF SELECTIONOF SELECTIONOF
DRYING BB
RUI CRKN- ICNL G
AY
BRICK-CLAY BRICK-CLAY
MANUFACTURING OF BRICKS

1
• Brick-clay should be free from harmful constituents.

SELECTION • It is necessary that a few sample bricks should be made first and the
SELECTIONOF suitability of the clay is judged from the product.
OF BRICK-
BRICK-CLAY
CLAY
• The proportion of different constituents of clay could then be adjusted.
 1.Unsoiling:
MANUFACTURING OF BRICKS
The top layer of the soil, about 200mm in depth, is taken out and
thrown away. The clay in top soil is full of impurities and hence it is to
2 be rejected for the purpose of preparing bricks.

2.Digging:
PS R The clay is then dug out from the ground. It is spread on the levelled
E LE EP CA TRIAOTNI O
ONF
ground, just a little deeper than the general level. The height of heaps
B ROI CF KC-LCALYA Y
of clay is about 600mm to 1200mm.

3.Cleaning:
The clay as obtained in the process of digging should be cleaned of
The clay for brick is prepared stones, pebbles, vegetable matters. If these particles are in excess, the
in the following order: clay is to be washed and screened. Such a process naturally will prove
to be troublesome and expensive.
Unsoiling
Digging 4.Weathering:
Cleaning The clay is then exposed to atmosphere for softening and mellowing.
Weathering The period varies from few weeks to full season. About 100 cu. ft of
Blending clay is required for manufacturing of 1000 no's of standard bricks.
Tempering
MANUFACTURING OF BRICKS 5.Blending:
The quality of brick-clay is to be improved by adding sand lime, alumina
2 and magnesia. This process is known as blending.

The blending indicates intimate or harmonious mixing. It is carried out

PS R by taking a small amount of clay every time and turning it up and down
E LE EP CA TRIAOTNI O
ONF in vertical direction.
B ROI CF KC-LCALYA Y

6.Tempering:
Then the mixed soil is tempered by being thoroughly broken up,
The clay for brick is prepared watered and kneaded.
in the following order:
The tempering should be done exhaustively to obtain homogeneous
Unsoiling mass of clay of uniform character.
Digging
Cleaning For manufacturing good bricks on a large scale, tempering is done in pug
Weathering mill. A typical pug mill is capable of tempering sufficient earth for a daily
Blending output of about 15000 to 20000 bricks.
Tempering
MANUFACTURING OF BRICKS 6.Tempering:

A pug mill is generally used to temper the clay.

2
This consists of a conical vessel of iron, 5 ft. 6 inch
high, partially (2 ft. 6 inch.) buried underground.
PS R
E LE EP CA TRIAOTNI O
ONF It is provided with a central revolving shaft to
B ROI CF KC-LCALYA Y which are attached horizontal blades. To these
horizontal blades, small vertical wedge-shaped
steel knives are fixed.

Feeding of clay and water is done through the top.

The shaft is rotated either by bullocks or by

mechanical power.

When tempering is complete, the clay is forced

out of an aperture at the base of the mill.
 MANUFACTURING OF BRICKS

Moulds are rectangular boxes with top or

3
bottom made of wood. Its size being
determined by the dimensions of brick required
after burning.
S EMLOE U
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NGOF
BRICK-CLAY It is a usual practice to make the internal
dimensions of the mould about 1/10 larger
than the size of the burnt bricks to allow for
shrinkage on burning.

Generally identification marks (frog mark) are

The clay which is prepared is then sent left on the face of the brick during the process
for the next operation of moulding of molding to indicate the name of the
manufacture of bricks.
 MANUFACTURING OF BRICKS I.HAND MOULDING
• In hand moulding , the bricks are moulded by hand i.e.; manually.
• It is adopted where manpower is cheap and is readily available for the
3 manufacturing process of bricks on a small scale.
• The moulds are rectangular boxes which are open at top and bottom.
• They may be of wood or steel.
S EMLOE U
C TL IDOI N
NGOF • The longer sides are kept slightly projecting to serve as handles.
BRICK-CLAY • The strips of brass or steel are sometimes fixed on the edges of wooden
moulds to make them more durable
• The steel moulds are more durable than wooden one and turn out bricks
of uniform size.

Following are two types of moulding: TWO METHODS OF HAND MOULDING

I.HAND MOULDING
II.MACHINE MOULDING TABLE MOULDING
GROUND MOULDING
On the other hand table
In ground molding the bricks
molding, they are made on a
are made on the ground usually
table usually with metal
in wooden moulds.
moulds.
 MANUFACTURING OF BRICKS

S EMLOE U
C TL IDOI N
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BRICK-CLAY

Following are two types of moulding:

I.HAND MOULDING
II.MACHINE MOULDING
 MANUFACTURING OF BRICKS II.MACHINE MOULDING
This type of moulding is carried out by two processes:
i) Plastic clay machine
3 ii) Dry clay machine

PLASTIC CLAY MACHINE:

The plastic clay machine combines the process of crushing, tempering
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and molding. In plastic clay machine the clay in plastic state is forced to
BRICK-CLAY
rectangular openings of a size equal to the length and breadth of the
bricks and are then cut into strips of thickness of the brick with wires in
frames. The bricks are called wire-cut bricks.

In this method, uniform size and density of bricks are secured.

Following are two types of moulding:
I.HAND MOULDING
II.MACHINE MOULDING
DRY CLAY MACHINE:
In dry clay machines, dry clay is reduced to powder, filled dry into
mould by the machine and then are subjected to high pressure to form
hard and well shaped bricks.

The bricks made by this process are very hard and compact.
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BRICK-CLAY

WIRE- CUT BRICKS

 Drying is usually done by placing the bricks in sheds
with open sides so as to ensure free circulation of air
and protection from bad weather and rains.
MANUFACTURING OF BRICKS
In Bangladesh brick molding is generally suspended
during the monsoons.
The bricks are allowed to dry till they are left with 5 to 7
4 percent moisture content. The drying period usually
varies from 7 to 14days.
In case of machine made bricks drying is performed by
SELECTIONOF circulating hot air or gases around the bricks.
DRYING
BRICK-CLAY
The moulded bricks are dried because of the following
reasons:
•If damp bricks or green bricks are directly taken to
burning then, they are likely to be cracked and
distorted
•To remove maximum moisture from the brick so as to
save time and fuel during burning
•To increase the strength of raw bricks so that they can
be handled and stacked in greater heights in the kiln
for burning without damage.
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Bricks are burnt in clamps or kilns, where the temperature is raised to
about 2100°F.
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At a temperature of about 1200°F, the organic matter present in the bricks
is oxidized and disappears.
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AY When the temperature raised to about 2100°F, certain chemical changes
take place in its constituent minerals giving new properties to the bricks.
Particles of alumina and sand bind themselves together and that increases
the density and strength of the bricks.

Fusible glass in small quantity is produced by burning of alumina and sand

When drying is complete, the bricks are
burnt for the following purposes:
1. To impart hardness and strength to
bricks.
2. To increase the density of bricks to make
them less absorbent to water.
grains. But when heated beyond 2100°F, the fusible glass is formed in a
much greater quantity and the bricks are said to be vitrified.
Vitrification softens the bricks and they begin to lose their shape.
Therefore, vitrification must be controlled so as to be just sufficient to
impart the required density and strength.

3. To gain durability and red color

appearance.
 (a)Clamp Burning
MANUFACTURING OF BRICKS
• A temporary structure generally constructed over the ground
with a height of about 4 to 6 m.
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• It is employed when the demand of the bricks is lower scale and
when it is NOT a monsoon season.
• A trapezoidal shape in plan with shorter end is slightly in
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excavation and wider end raised at an angle of 15 degrees from
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ground level.
• A brick wall with mud is constructed on the short end and a
layer of 70cm to 80cm thick fuel (grass, cow dung, ground nuts,
wood or coal) laid on the floor.
Bricks can be burnt using the following
• A layer consists of 4 or 5 courses of raw bricks laid on edges with
methods:
small spaces between them for circulation of air.
(a) Clamp Burning
(b) Kiln Burning • A second layer of fuel is then placed, and over it another layer
of raw bricks is laid. The total height of clamp in alternate layers of
brick is about 3 to 4 m.
• After these alternate layers of the bricks and fuel, it is plastered
with mud on sides and top and filled with earth to prevent the
escape of heat.
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Bricks can be burnt using the following

methods:
(a) Clamp Burning
(b) Kiln Burning
 (a)Clamp Burning
MANUFACTURING OF BRICKS
• Fire is ignited at the bottom, once fire is started it is kept under fire by
itself for one or two months and same time period is needed for the
5 cooling of the bricks.

• Burnt bricks are taken out from the clamp.

SELECTIONOF Disadvantages of Clamp Burning:
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AY 1. Bricks at the bottom are over-burnt while at the top are under-burnt.
2. This method cannot be employed for the manufacturing of large
number of bricks and it is costly in terms of fuel because large amount
of heat is wasted.
3. It cannot be employed in monsoon season.
Bricks can be burnt using the following
methods:
(a) Clamp Burning
(b) Kiln Burning

MANUFACTURING OF BRICKS
5 Kiln is a large oven used for the burning of bricks by
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Bricks can be burnt using the following
methods:
(a) Clamp Burning
(b) Kiln Burning
(b)Kiln Burning
KILN:
1) Intermittent kilns
2) Continuous kilns
a) Bull’s trench kiln
b) Hoffman’s kiln
c) Tunnel kiln
Kilns are permanent structures and they are adopted to manufacture
bricks on a large scale. Generally coal and other locally available materials
like wood, cow dung etc. can be used as fuel.
KILN BURNING:
• Kiln burning is preferred when bricks are required to be manufactured in
large quantities.
• The kiln consists of a regular walled structure with proper arrangements
for heating and the bricks are arranged in regular stacks.
• There are various types of kilns. The most common one is Hoffman's Kiln.
 MANUFACTURING OF BRICKS (b)Kiln Burning

Hoffman's Kiln:
5 • This kiln is constructed over ground, also known as flame kiln.

• Its shape is circular in plan and it is divided into a number of

SELECTIONOF compartments or chambers each of which is connected by a flue to
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• Each compartment is also provided with a door opening outward

for loading and unloading bricks.

Bricks can be burnt using the following • When the compartments are in use, the doorway is closed by dry
methods: bricks and sand, and the joints are closed by mud filling. Holes are
(a) Clamp Burning provided on the top of each compartment, and through these
(b) Kiln Burning holes, fuel (powdered coal) is dropped

• A permanent roof is provided; the kiln can even function during

rainy season.
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Bricks can be burnt using the following

methods:
(a) Clamp Burning
(b) Kiln Burning
 (b)Kiln Burning
MANUFACTURING OF BRICKS
Hoffman's Kiln:
• Each compartment of the kiln has a specific function to perform.
5 Chamber 1 - loading
Chamber 2 to 5 – drying and pre-heating
Chambers 6 and 7 - burning
SELECTIONOF Chambers 8 to 11 - cooling
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• Due to continuity in operation form the loading of the new bricks,

this type of kiln is also termed as continuous kiln.

Bricks can be burnt using the following • One cycle of loading, drying, burning, cooling and emptying may
methods: take as much as two weeks.
(a) Clamp Burning The initial cost of installing this kiln is high, the following advantages
(b) Kiln Burning :

(i) Good quality bricks are produced

(ii) It is possible to regulate heat inside the chambers through fuel
holes.
(iii) Supply of bricks is continuous and regular
(iv) There is considerable saving in fuel due to pre heating of raw bricks
by flue gases.
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Bricks can be burnt using the following

methods:
(a) Clamp Burning
(b) Kiln Burning
 THANK YOU
Amity Kundu, Senior Lecturer, NSU
B.P.S in Arch, State University of New York at Buffalo
M.Arch, University of Pennsylvania, USA
Email: amity.kundu@northsouth.edu