Brick Masonry -

History, types, manufacturing and properties.

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History

History of Bricks:
Bricks are one of the oldest types of building blocks.


They are an ideal building material because they are relatively
cheap to make, very durable, and require little maintenance.
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A brick is a block of ceramic material used in masonry
construction, usually laid using various kinds of mortar.



History of Bricks:
Bricks dated 10,000 years old were found in the
Middle East.
Examples of the civilizations who used mud brick
are the ancient Egyptians and the Indus Valley
Civilization, where it was used exclusively. In
particular, it is evident from the ruins of Buhen,
Mohenjo-Daro and Harappa.
The first sun-dried bricks dpy;
were made in Mesopotamia (what is now Iraq), in
the ancient city of Ur in about 4000 BC


After the foundations have been completed the
walls are set out and construction commences.
Walls
Walls can be classified in a number of ways:-
Solid
Cavity
Internal
External
Load bearing or
Non load bearing


Load bearing supporting roofs, floors etc.
Non load bearing Dividing spaces
Main functions of walls
1. Strength
2. Stability
3. Weather exclusion
4. Thermal Insulation
5. Sound Insulation
6. Durability
7. Fire resistance
8. Appearance
Part of a cavity wall with the internal
skin removed to expose the
Insulation
Bonding of Brickwork / Blockwork
Bonding of brickwork is the
arrangement of brickwork in a wall,
column or pier which will give maximum
overlap and no continuous vertical
joints. The purpose of bonding is to:-

1. Obtain maximum strength whilst
distributing the loads carried by the
walls.
2. Ensure lateral stability and
resistance to side thrusts.
3. Create an acceptable appearance.
LOAD
Possible settlement
Unbonded walls Comparatively weak and liable to fail under load or lateral
thrust.
Bonding of Brickwork / Blockwork
Bonded wall load is
distributed over the whole
wall and has greater
resistance to side thrust.
Standard brick sizes
Length + one mortar joint =225mm

Width + one mortar joint =112.5mm

Height + one mortar joint =75mm

Mortar joint thickness = 10mm
LOAD

SPREAD OF LOAD

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Header
Row lock
Stretcher
Soldier
Brick position
Technical terms used in brick masonry
Header
Brick which is laid with its length perpendicular to the face of the
wall.

Stretcher
Full brick which is laid with its length parallel to the face of the wall.

Course
Horizontal layer of brick.

Header course
Course of brick work fully composed of header

Stretcher course
Course of brick work fully composed of stretchers.
Half bat
Queen closer
King closer
Closer
Portion of brick cut in such a manner that one long face remains uncut.

King closer
Brick is cut in such a way that the width of its end is half of full brick.

Queen closer
Brick is half as wide as a full brick.

Half Bat
Portion of brick cut half across the width.

Bevelled closer
It is similar to king closer with the only difference that the whole length
of he brick is bevelled.

Brick Bond:
Bond the arrangement of bricks in rows (courses).
Bonds are designed for:
Appearance
To tie together a structural or outer wall (wythe) to an
inner wall
Wythe a vertical section of wall one brick thick

Brick Work
Brick laying
Material that was used in
mortar (mix of cement or
lime with sand or both
Ratio; binder : sand = 1:3
Thickness or mortar
normally in range 6.5mm -
9mm
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Brick Work
Brick lying finishing: Normally, brick lying will followed by
brick lying finishing. The objective is to get good appearance
or good finishing to brick lying joint.
It can be make slowly without fully complete or after it
complete
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Mortar
dikemaskan
Mortar lebihan
dikeruk & di buang
sedalam 15mm
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Masonry Joints
Concave
Flush
Racked
Struck
Weathered
Vee
Brick work
Brick arrangement in
brickwork
Some of the popular brick
arrangement is:
Brick edge Arrangement
Brick head
Arrangement
American Arrangement
English Arrangement
Flemish Arrangement
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American
Arrangmen
t
Stretcher Bond
This is the simplest and most widely used bond. It
is used for half brick walls and cavity walls. The
bricks must lap over each other in successive
courses in a fashion similar to the one shown
below.
Half lapped
Formation of a corner in stretcher bond
bat to form
stopped end
Racking-back


Wall tie
Quoin
Cavity
D.P.C.
Horizontal
mortar joint
Perpendicular
mortar joint
Return corner of a cavity wall in stretcher
bond including wall ties and DPC
Header course
Stretchers course
Queen closer
ISOMETRIC VIEW OF
ENGLISH BOND
ISOMETRIC VIEW OF

FLEMISH BOND
Header
Stretcher
Advantages of bricks :

Brick will not burn, buckle or melt.
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Brick will not rot and allow Termites to invade.
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Brick will not rust and corrode.
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Brick will not fade from the Sun's UV Rays.
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Brick will not be damaged by high winds, rain or hail.

Brick will not require constant maintenance.
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Brick will not limit your personal expression.

* Brick will not limit your design options.
General Characteristics of Bricks
Brick is made of clay or shale formed, dried and fired into
a durable ceramic product.

There are three ways to form the shape and size of a brick:
Extruded (stiff mud), Kiwik
Molded (soft mud) Kiwik
Dry-pressed. Kiwik

The majority of brick are made by the extrusion method.

Brick achieves its color through the minerals in the
fired clay or through coatings that are applied before or
after the firing process. This provides a durable color
that never fades or diminishes.

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Brick shrink during the manufacturing process as
vitrification occurs.

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The method used to form a brick has a major impact on
its texture.
Sand-finished surfaces are typical with molded brick.
A variety of textures can be achieved with extruded brick.

Brick manufacturers address sustainability by locating
manufacturing facilities near clay sources to reduce
transportation, by recycling of process waste, by
reclaiming land where mining has occurred, and by
taking measures to reduce plant emissions. Most brick
are used within 500 miles of a brick manufacturing
facility.
Raw material for clay:
Clay is one of the most abundant natural mineral
materials on earth. For brick manufacturing, clay must
possess some specific properties and characteristics.
Such clays must have
plasticity, which permits them to be shaped or molded
when mixed with water; they must have
sufficient wet and air-dried strength to
maintain their shape after forming.

Also, when subjected to appropriate temperatures, the
clay particles must fuse together.
clay are composed of
silica
alumina
with varying amounts of metallic oxides.
(particularly those of iron, magnesium and calcium)

Bricks
Manufacture - 4 stages
Material preparation
Manufacturing
drying
Firing
Preparation: material
(clay) washed and grinding
(fineness)
41
Sample of grinding machine
for clay
Sample of crushing machine
Brick
Manufacturing : Clay will
grinded with 15% of water. The
clay will be pushed through the
mould base on the shape. After
that, Clay will cut to get a
standard size of brick using wire.
Sometimes, bricks will produced
using big mould that clay will be
press that using hydraulic
machine (This method, clay will
grind 10% of water) or without
hydraulic press (with 30% of
water)
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After bricks in form,
identification or
perforation to the bricks.
Drying : Wet unit bricks
will be drying in space or
room with control
temperature to make sure
the bricks in complete dry.
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Brick was compile
before bring to the
kiln
Firing : Dry bricks, was
compile in kiln to firing
process with 600
o
C
(temperature). This is for
burn the carbon and sulfur
that have remain.After
that, temperature will
increase to 900
o
C to get a
vetrification process.
Normally, vitrification
process occurred around
800
o
C.
Bricks become hard/strong
after vitrification process.
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Bricks
Bricks manufacturing process
flow
MATERIAL PREPARATION
Manufacturing
Manufacturing
Setting
Firing Process
Packaging
PROPOERTIES OF BRICKS
The most important properties of brick are

1) durability -
2) color -
3) texture -
4) size variation -
5) compressive strength -
6) absorption. -
Durability:
The durability of brick depends upon achieving
incipient fusion and partial vitrification during firing.
Because compressive strength and absorption values are
also related to the firing temperatures, these properties,
together with saturation coefficient, are currently taken
as predictors of durability in brick specifications.
However, because of differences in raw materials and
manufacturing methods, a single set of values of
compressive strength and absorption will not reliably
indicate the degree of firing.

Texture:
Coatings and Glazes : Many brick have smooth or sand-
finished textures produced by the dies or molds used in
forming.
A smooth texture, commonly referred to as a die skin
results from pressure exerted by the steel die as the clay
passes through it in the extrusion process. Most
extruded brick have the die skin removed and the
surface further treated to produce other textures using
devices that cut, scratch, roll, brush or otherwise
roughen the surface as the clay column leaves the die
Brick may be tumbled before or after firing to achieve an
antique appearance.
Color:
The color of fired clay depends upon its chemical composition,
the firing temperatures and the method of firing control.
Of all the oxides commonly found in clays, iron probably has
the greatest effect on color. Regardless of its natural color, clay
containing iron in practically any form will exhibit a shade of
red when exposed to an oxidizing fire because of the formation
of ferrous oxide. When fired in a reducing atmosphere, the
same clay will assume a dark (or black) hue. Creating a
reducing atmosphere in the kiln is known as flashing or
reduction firing.
Given the same raw material and manufacturing method,
darker colors are associated with higher firing temperatures,
lower absorption values and higher compressive strength
values. However, for products made from different raw
materials, there is no direct relationship between strength and
color or absorption and color.
Size Variation
Because clays shrink during both drying and firing,
allowances are made in the forming process to achieve the
desired size of the finished brick. Both drying shrinkage and
firing shrinkage vary for different clays, usually falling within
the following ranges:
Drying shrinkage: 2 to 4 percent
Firing shrinkage: 2.5 to 4 percent
Firing shrinkage increases with higher temperatures, which
produce darker shades. When a wide range of colors is
desired, some variation between the sizes of the dark and
light units is inevitable.
To obtain products of uniform size, manufacturers control
factors contributing to shrinkage. Because of normal
variations in raw materials and temperature variations within
kilns, absolute uniformity is impossible. Consequently,
specifications for brick allow size variations.
Compressive Strength and Absorption
Both compressive strength and absorption are affected
by properties of the clay, method of manufacture and
degree of firing.
For a given clay and method of manufacture, higher
compressive strength values and lower absorption
values are associated with higher firing temperatures.
Although absorption and compressive strength can be
controlled by manufacturing and firing methods, these
properties depend largely upon the properties of the
raw materials.

Tests on bricks:
Clay Masonry Units -ASTM C 67, Standard Test Methods
for Sampling and Testing Brick and Structural Clay Tile
These test methods cover
Procedures for the sampling and testing of brick and
structural clay tile.
Tests include modulus of rupture, compressive strength,
absorption, saturation coefficient, effect of freezing and
thawing, efflorescence, initial rate of absorption and
determination of weight, size, warpage, length change, and
void area.

Brick Work
Brick shape in
brick work
To produce the
variety of
arrangmenet or
special purpose
in brick work
59
Brick Work
Brick shape in
brick work
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Angle
Brick
Brick Work
Brick shape in
brick work
61
Brick Work
Brick
arrangement in
brick work
62
Brick work
Brick
arrangement in
brick work
63
Brick Work
Brick
arrangement in
brick work
64
Brick Work
Brick
arrangement in
brick work
65
Brick Work
Plastering
These have been done after brick lying finishing. The
purpose is to get a smooth surface and uniformity in color.
The wall should scratch to get a rough surface that will
easy when plastering work
Materials that was used : lime, cement Portland, gypsum
Plastering work should be in two layers, which one base
layer and finishing layer.
Base layer ; cement :Lime : sand = 1:2:8-9 @ 1:1: 5-6 @
cement : sand = 1:3 @ gysum : sand = 1:1-3 @ gypsum : lime
: sand = 1:3:7-9
Finishing layer; lime : gypsum = 1: 0.25 - 0.5
66
Photo advantages of brick
67
Decorative of brick work
Walk way
68
Photo advantages of brick
The
End
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Brick Bond:
Bond the arrangement of bricks in rows (courses).
Bonds are designed for:
Appearance
To tie together a structural or outer wall (wythe) to an
inner wall
Wythe a vertical section of wall one brick thick

Test on bricks

To know the quality of bricks following 7 tests can be
performed. In these tests some are performed in
laboratory and the rest are on field.
1. Compressive strength test
2. Water Absorption test
3. Efflorescense test
4. Hardness test
5. Size, Shape and Color test
6. Soundness test
7. Structure test

Compressive strength test
Compressive strength test: This test is done to know
the compressive strength of brick. It is also called
crushing strength of brick. Generally 5 specimens of
bricks are taken to laboratory for testing and tested
one by one. In this test a brick specimen is put on
crushing machine and applied pressure till it breaks.
The ultimate pressure at which brick is crushed is
taken into account. All five brick specimens are tested
one by one and average result is taken as brick's
compressive/crushing strength.

Water Absorption test
Water Absorption test: In this test bricks are
weighed in dry condition and let them immersed in
fresh water for 24 hours. After 24 hours of immersion
those are taken out from water and wipe out with
cloth. Then brick is weighed in wet condition. The
difference between weights is the water absorbed by
brick. The percentage of water absorption is then
calculated.

The less water absorbed by brick the greater its
quality. Good quality brick doesn't absorb more than
20% water of its own weight.

Efflorescense test
Efflorescense test: The presence of alkalies in bricks is
harmful and they form a gray or white layer on brick
surface by absorbing moisture. To find out the presence of
alkalis in bricks this test is performed. In this test a brick is
immersed in fresh water for 24 hours and then it's taken
out from water and allowed to dry in shade.

If the whitish layer is not visible on surface it proofs that
absence of alkalis in brick. If the whitish layer visible about
10% of brick surface then the presence of alkalis is in
acceptable range. If that is about 50% of surface then it is
moderate. If the alkalis's presence is over 50% then the
brick is severely affected by alkalies

Hardness test
Hardness test: In this test a scratch is made on brick
surface with a hard thing. If that doesn't left any
impression on brick then that is good quality brick.

Size, shape and color test: In this test randomly
collected 20 bricks are staked along lengthwise,
widthwise and heightwise and then those are
measured to know the variation of sizes as per
standard. Bricks are closely viewed to check if its edges
are sharp and straight and uniform in shape. A good
quality brick should have bright and uniform color
throughout.

Soundness test
Soundness test: In this test two bricks are held by
both hands and struck with one another. If the bricks
give clear metallic ringing sound and don't break then
those are good quality bricks.

Structure test
Structure test: In this test a brick is broken or a
broken brick is collected and closely observed. If there
are any flows, cracks or holes present on that broken
face then that isn't good quality brick.

Tools used
Trowel
Plumb bob
Hammer
Spirit level
Mason square
Steel tape
Mason Square
Plumb Bob
Steel tape
84
Masonry Joints
Concave
Flush
Racked
Struck
Weathered
Vee