Beruflich Dokumente
Kultur Dokumente
Table of Contents
AR6204
BUILDING MATERIALS
- II
1ST YEAR [2ND SEM]
UNIT - 1
BRICKS
By
Ar.B.RAMEEZ MOHAMED
Ar.R.GOWTHAM
Table of Contents
Table of Contents
Bricks_____________________________________________________________________________________1
INTRODUCTION_________________________________________________________________________1
COMPARISON BETWEEN BRICKWORK AND STONEWORK________________________________1
COMPOSITION OF GOOD BRICK EARTH_________________________________________________2
HARMFUL INGREDIENTS IN BRICK______________________________________________________3
MANUFACTURE OF BRICKS_____________________________________________________________4
PREPERATION OF CLAY_________________________________________________________________5
PUG MILL______________________________________________________________________________6
MOULDING OF BRICKS__________________________________________________________________8
HAND MOULDING OF BRICKS__________________________________________________________8
MACHINE MOULDED BRICKS:__________________________________________________________9
DRYING OF BRICKS____________________________________________________________________10
Artificial drying________________________________________________________________________10
Circulation of air________________________________________________________________________10
Drying yard____________________________________________________________________________10
Period for drying________________________________________________________________________10
Screens_______________________________________________________________________________10
BURNING OF BRICKS___________________________________________________________________11
CLAMPS_____________________________________________________________________________11
Advantages of Clamp Burning_____________________________________________________________12
Disadvantages of Clamp burning___________________________________________________________13
KILNS_______________________________________________________________________________13
Intermittent Kilns_______________________________________________________________________13
Intermittent up-draught Kilns______________________________________________________________13
Intermittent down-draught kilns____________________________________________________________14
CONTINUOUS KILNS__________________________________________________________________15
Bulls Trench Kiln_______________________________________________________________________15
_________________________________________________________________________________________16
Hoffmans kiln_________________________________________________________________________16
Table of Contents
Tunnel kiln____________________________________________________________________________18
COMPARISON BETWEEN CLAMP-BURNING AND KILN BURNING__________________________21
QUALITY OF GOOD BRICKS___________________________________________________________22
FACTORS AFFECTING QUALITY OF BRICKS_____________________________________________22
TESTS FOR BRICKS___________________________________________________________________23
ABSORPTION_________________________________________________________________________23
CRUSHING STRENGTH________________________________________________________________23
HARDNESS___________________________________________________________________________23
SHAPE & SIZE________________________________________________________________________23
PRESENCE OF SALTS__________________________________________________________________24
SOUNDNESS__________________________________________________________________________24
STRUCTURE__________________________________________________________________________24
CLASSIFICATION OF BRICKS___________________________________________________________24
UN burnt or Sun dried bricks______________________________________________________________24
Burnt Bricks___________________________________________________________________________25
Second class bricks______________________________________________________________________25
Third class bricks_______________________________________________________________________25
Fourth class bricks______________________________________________________________________25
USES OF BRICKS______________________________________________________________________26
Unit -1: bricks
Bricks
INTRODUCTION
Common brick is one of the oldest building material and extensively used at the
present as a leading material of construction.
One of the oldest building material- the Great Wall of China (210 B.C) was built with
both, burnt and sun dried bricks. Bricks were also used in early Roman Civilizations.
Obtained by molding clay in rectangular blocks of uniform size and then by drying and
burning of those blocks.
Bricks are most widely used because of its strength, reliability, low cost, easy
availability etc.
At present, India has the production capacity to manufacture over 1, 00,000 million
bricks through about 45000 local kilns in the unorganized sector.
The construction industry is largely dependent on the small sector which is unable to
deliver high quality bricks in view of rising fuel cost, outdated technology and lower
efficiency of production.
Places where stone is not easily available but there is plenty of clay, the brickwork
becomes easier and cheaper.
Good quality bricks resist various atmospheric effects in a better way than stones.
Its size enables easy handling and placement in walls and easy connections and
openings.
For public and monumental structures, stonework is more useful as brickwork do not
create a solid appearance.
1) Alumina:
When present in excess, with inadequate sand, the raw bricks shrink
during drying and burning become too hard.
2) Silica:
3) Lime:
The excess of lime causes the brick to melt and loose its shape.
4) Oxide of Iron:
The excess of lime causes the brick to melt and loose its shape.
5) Magnesia:
It decreases shrinkage
6) Lime:
7) Iron Pyrites:
8) Alkalis:
The alkalis act as flux in the kiln during burning and they cause
bricks to fuse, twist and warp.
As a result the bricks are melted and they lose their shape.
9) Pebbles:
MANUFACTURE OF BRICKS
In the process of manufacturing bricks, the following four distinct operations are involved:
1. PREPERATION OF CLAY
Un-soiling
Digging
Cleaning
Weathering
Blending
Tempering
2. MOULDING
Hand Moulding
Machine Moulding
3. DRYING
Natural burning
Artificial Burning
4. BURNING
Clamp burning
Kiln burning
PREPERATION OF CLAY
In the process of manufacturing bricks, the following four distinct operations are involved:
1. UN-SOILING
2. DIGGING
Clay dug out from ground is spread on levelled ground (just a little deeper than the
general level) in about 60cm to 120cm heaps.
3. CLEANING
Stones, pebbles, vegetable matter, etc. are removed and lumps of clay are converted
into powder form.
4. WEATHERING
Clay is exposed to atmosphere from few weeks to full season for softening and
mellowing. (Preferably dug before monsoon)
5. BLENDING
Clay is made loose and any ingredient to be added to it is spread out at top and blended
by turning it up and down in vertical direction.
6. TEMPERING
Clay is brought to a proper degree of hardness, then water is added to clay and whole
mass is kneaded or pressed under the feet of men or cattle. For large scale, tempering is
usually done in pug mill as shown in the figure.
PUG MILL
For manufacturing quality bricks, tempering is done in pug mills and the operation is called
pugging.
A vertical shaft with horizontal arms which are fitted with knives is provided at the
center.
The central shaft is rotated with the help of bullocks which are tied at the end of long
arms.
Alternatively, steam, diesel or electric power may also be provided for the same
purpose.
The clay which is blended is mixed with water and is fed into the pug mill from the
top.
The knives cut through the clay and break all the lump clays when the shaft rotates.
The pugged clay is taken out from the opening provided at the bottom.
MOULDING OF BRICKS
Clay, which is prepared from pug mill, is sent for the next operation of moulding. Following
are the two ways of moulding.
Hand Moulding
Machine Moulding
Steel moulds are more durable and used for manufacturing bricks on large scale as shown in
figure.
Ground moulding:
Ground is first made level and fine sand is sprinkled over it.
Mould is dipped in water and placed over the ground to fill the clay.
Extra clay is removed by wooden or metal strike after the mould is filled forced mould
is then lifted up and raw brick is left on the ground.
Mould is then dipped in water every time lower faces of ground moulded bricks are
rough and it is not possible to place frog on such bricks.
Ground moulded bricks of better quality and with frogs on their surface are made by
using a pair of pallet boards and a wooden block.
The bricks made when mould is dipped in water are called as Slog moulded bricks.
The bricks made when mould is sprinkled with sand are called as sand moulded bricks.
Table moulding:
Process of moulding these bricks is just similar to ground bricks on a table of size
about 2m x 1m.
This machine containing rectangular opening of size equal to length and width of a
brick.
Pugged clay is placed in the machine and as it comes out through the opening, it is cut
into strips by wires fixed in frames, so these bricks are called wire cut bricks.
In these machines, strong clay is first converted into powder form and then water is
added to form a stiff plastic paste.
Such paste is placed in mould and pressed by machine to form hard and well-shaped
bricks.
DRYING OF BRICKS
The damp bricks, if burnt, are likely to be cracked and distorted.
Hence moulded bricks are dried before they are taken for the next operation of burning.
Bricks are laid along and across the stock in alternate layers.
Artificial drying
Drying by tunnels usually 120C about 1 to 3 days
Circulation of air
Stacks are arranged in such a way that sufficient air space is left between them free
circulation of air.
Drying yard
Special yards should be prepared slightly higher level prevent the accumulation of rain
water.
Screens
Screens are necessary, may be provided to avoid direct exposure to wind or sun.
BURNING OF BRICKS
If such clay is cooled back, it absorbs moisture from air and gets hydrated back to its
original state.
Such poorly burnt clay is unstable. However, if clay is heated up to 700-1000 deg C
chemical changes take place by which alumina and silica in clay fuse together resulting
in a compound which is strong and stable.
1. Clamps
2. Kilns.
Clamps are temporary structures and they are adopted to manufacture bricks on small
scale.
Kilns are permanent structures and they are adopted to manufacture bricks on a large
scale.
CLAMPS
A typical clamp is shown in figure
A piece of ground is selected. Its generally trapezoidal in shape. The clamp is raised at
an angle of about 15 deg from the ground level.
A brick wall is constructed on the short end and the fuel is laid on the prepared floor.
The fuel may consist of grass, cow dung, litter, husks of rice or ground nuts, etc.
The thickness of this layer is 700-800mm. The wood or charcoal may also be used as
fuel.
The layer consisting of 4-5 courses of bricks is then put up. The bricks are laid on
edges with small spaces between them for the circulation of air.
The second layer of fuel is placed and over it another layer of bricks is put up.
The total height of the clamp is 3-4m. When about one third of the height is reached
the clamp is lit up.
Not possible to regulate fire in a clamp once it starts burning and bricks are burnt in an
uneven way.
Quality of Bricks is not uniform. Bricks near the bottom are over burnt and bricks near
the sides are under burnt.
KILNS
A kiln is a large oven, which is used to burn bricks by
1. Intermittent kilns
2. Continuous kilns
Intermittent Kilns
These are intermittent in operation, which means that they are loaded, fired, cooled and
unloaded.
Wide doors provided at each ends for loading and unloading of kilns.
The flues are channels or passages which are provided to carry flames or hot gases
through the body of the kiln.
They are provided with permanent walls and closed tight roofs.
The floor of the kiln has openings which are connected to a common chimney stack
through flues.
The working of this kiln is more or less similar to up-draught kilns- but the
arrangement is such that the hot gases are carried through vertical flues up to the level
of roof and then released.
These hot gases move downward by the chimney draught and in doing so, they burn
the bricks.
CONTINUOUS KILNS
These are continuous in operation.
That means loading, firing, cooling and unloading are carried out simultaneously in
these kilns.
Hoffmans kiln
Tunnel kiln
It has no roof and can only be used outside the monsoon season.
Dampers are in the form of iron plates- used to divide the kilns in suitable sections.
Hoffmans kiln
Constructed over ground, also known as flame kiln.
o Fuel holes with covers to drop fuel, which may be in the form of powdered
coal, into burning chambers.
o The main doors are closed by dry bricks and covered with mud when required.
o For communicating doors and radial flues, the dampers are provided to shut or
open them.
Advantages:
Possible to
regulate the heat
inside.
Considerable
saving in fuel
due to pre-
heating of raw
bricks
No air pollution
in the locality
Tunnel kiln
This type of kiln is in the form of tunnel which may be straight, circular or oval in
plan.
The raw bricks are placed on trolleys which are then removed from one end to the
other end of tunnel.
This kiln proves to be economical when bricks are to be manufactured on a large scale
TRADITIONAL INDIAN
CLAY BRICK KILN
BRICK CLAMP
It may be noted that the strength of brick-work mainly depends on the type of mortar
used and not so much on the individual strength of the bricks.
1. ABSORPTION
2. CRUSHING STRENGTH
3. HARDNESS
6. SOUNDNESS
7. STRUCTURE
ABSORPTION
Water Absorption in Bricks is carried out by immersing it in water for 24 hrs.
It is again weighed and the diff is in wt. indicates the amount of water absorbed by
Bricks.
CRUSHING STRENGTH
Crushing strength of a brick is found out by placing it in a compression testing
machine.
HARDNESS
In this test, a scratch is made on brick surface with the help of finger nail.
PRESENCE OF SALTS
The soluble salts, if present in bricks will cause efflorescence in the surface of bricks.
For finding out the presence of soluble salts in a brick, it is immersed in water for 24
hrs.
The absence of grey or white deposits in its surface indicates absence of soluble salts.
If the white deposit cover about 10% surface, the efflorescence are said to be as
moderate; when deposits are to be more than 50%, the efflorescence become heavy and
it is treated as serious when such deposits are converted into powdery mass.
SOUNDNESS
In this test, two bricks are taken and then struck together with each other, the bricks
should not break and a clear ringing sound should be produced.
STRUCTURE
A brick is broken and its structure is examined.
CLASSIFICATION OF BRICKS
Bricks can broadly be divided into two categories.
These bricks can only be used in the constructions of temporary and cheap structures.
Burnt Bricks
The bricks used in construction works are burnt bricks and they are classified into the
following four categories.
First Class bricks:
o The surface and edges of the bricks are sharp, square, smooth and straight.
o They comply all the qualities of good bricks and used for superior work of
permanent nature.
o These bricks are ground moulded and they are burnt in kilns.
o The surface of bricks is somewhat rough and shape is also slightly irregular.
o These bricks are commonly used at places where brick work is to be provided
with a coat of plaster.
o These bricks are not hard and they have rough surfaces with irregular and
distorted edges.
o They are used for unimportant and temporary structures and at places where
rainfall is not heavy.
o These are over burnt bricks with irregular shape and dark colour.
o These bricks are used as aggregate for concrete in foundation, floors, roads, etc.
because of the fact that the over burnt bricks have compacted structure and
hence, they are sometimes found stronger than even first class bricks.
USES OF BRICKS
The first class and second class bricks are used for all sorts of sound work especially of
permanent nature. These include buildings, dams, roads, sewers, bridge piers, tunnels,
pitching work etc.
The use of first class bricks is specified for obtaining the architectural effects on the
faces of structures where they are to be kept exposed for beauty.
The masonry with second class bricks is generally plastered to make the smooth
surface obtained due to irregular shape and size of bricks. The mortar required in brick
masonry using second class bricks will also be more.
The third class and sun-dried bricks are used for construction work of temporary
nature. These bricks are not used in damp situations or at places subjected to heavy
rains.
Fourth class bricks are used as road metal and as aggregates in the foundation concrete.