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SIGMA COLLEGE OF ARCHITECTURE

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.

COMPARISON BETWEEN BRICKWORK AND STONEWORK

Bricks are superior to stonework in following respects.

Places where stone is not easily available but there is plenty of clay, the brickwork
becomes easier and cheaper.

Cost of construction is less as less skilled laborers are involved.

No complicated lifting devices are necessary.

Good quality bricks resist various atmospheric effects in a better way than stones.

Bricks have greater fire resistance than stone or concrete masonry.

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Its size enables easy handling and placement in walls and easy connections and
openings.

It can be easily adapted to small-scale and large-scale structures to give pleasing


appearance and texture.

Bricks are inferior to stonework in following aspects.

Brickwork is less water tight than stonework- they absorb moisture

For public and monumental structures, stonework is more useful as brickwork do not
create a solid appearance.

Stonework is solid than brick work.

Architectural effects of better quality can be developed by stonework.

Its cheaper where stone is available in plenty.

COMPOSITION OF GOOD BRICK EARTH


Following are the constituents of good brick earth.

1) Alumina:

Main constituent of every kind of clay.

Good brick: 20% -30% of alumina.

Alumina gives plasticity to earth so it can be molded.

When present in excess, with inadequate sand, the raw bricks shrink
during drying and burning become too hard.

2) Silica:

Exists in clay as free or combined

Mixed with clay in combined form with alumina

Good brick: 50% - 60% of silica.

Silica gives uniform shape to bricks.

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Durability depends on the proportion of silica present.

When present in excess, destroys cohesion between particles and


bricks become brittle.

3) Lime:

It should be present in very small quantities not exceeding 5%

It helps in fusing sand (alone infusible) which then acts as


cementing material for brick particles.

It should be very finely powdered else on burning the lumps will


convert to quicklime which expands in presence of moisture
resulting in splitting of bricks.

The excess of lime causes the brick to melt and loose its shape.

4) Oxide of Iron:

It is added in small quantity 5-6%

It helps sand to fuse sand

Imparts red colour on burning It should be very finely powdered


else on burning the lumps will convert to quicklime which expands
in presence of moisture resulting in splitting of bricks.

The excess of lime causes the brick to melt and loose its shape.

5) Magnesia:

A small amount of MgO imparts yellow color to the brick

It decreases shrinkage

Its excess leads to decay of brick

HARMFUL INGREDIENTS IN BRICK


Following are the ingredients which are undesirable in brick earth.

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6) Lime:

Excess lime causes brick to melt and lose its shape.

7) Iron Pyrites:

If iron pyrites are present, the bricks are crystallized and


disintegrated during burning because of the oxidation of the iron
pyrites.

8) Alkalis:

These are mainly in the form of soda and potash.

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.

Further, the alkalis remaining in bricks will absorb moisture from


the atmosphere, when bricks are used in masonry. Such moisture,
when evaporated, leaves behind grey or white deposits on the wall
surface.

9) Pebbles:

The presence of pebbles or grits of any kind is undesirable in brick


earth because it will not allow the clay to be mixed uniformly and
thoroughly which will result in weak and porous bricks.

10) Organic Matter:

The presence of vegetation and organic matter in brick earth assists


in burning.

But if such matter is not completely burnt, the bricks become


porous.

MANUFACTURE OF BRICKS

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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

Top layer of 20cm- 30cm depth is removed as it contains impurities.

2. DIGGING

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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.

The process of tempering is done with the help of pug mill.

PUG MILL
For manufacturing quality bricks, tempering is done in pug mills and the operation is called
pugging.

It has a conical iron tube as shown is fig.

The mill is sunk 60cm into the ground.

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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.

The yield from pug mill is about 1500 bricks.

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IMAGE 1: The process of tempering with the help of cattle or by men.

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IMAGE 2: PUG MILL

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.

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Hand Moulding

Machine Moulding

HAND MOULDING OF BRICKS


Moulds are rectangular boxes of wood or steel, which are open at top and bottom.

Steel moulds are more durable and used for manufacturing bricks on large scale as shown in
figure.

Bricks prepared by hand moulding are of two types.

Ground moulded bricks

Table moulded bricks

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.

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Ground moulded bricks Types of Moulds

MACHINE MOULDED BRICKS:


This method proves to be economical when bricks in huge quantity are to be manufactured at
the same spot. It is also helpful for moulding hard and strong clay.

These machines are broadly classified in two categories

(a) Plastic clay machines

(b) Dry clay machines

Plastic clay machines:

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.

Dry clay machines:

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.

They carry distinct frogs and exhibit uniform texture.

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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.

The drying of brick is by the following means

Artificial drying
Drying by tunnels usually 120C about 1 to 3 days

Used when bricks are to be dried rapidly on a large scale.

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.

Period for drying


Usually about 3 to 10 days for bricks to become dry

Screens
Screens are necessary, may be provided to avoid direct exposure to wind or sun.

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BURNING OF BRICKS

This is very important operation in the manufacturing of bricks to impart hardness,


strength and make them dense and durable.

Heating clay up to 640 degree C produces physical changes.

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.

Burning of bricks is done either

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

The procedure adopted in constructing a clamp is as follows

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.

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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.

Then the clamp is allowed to burn for one to two months.

It is then allowed to cool for more or less the same period.

Then the bricks are taken out from the clamp.

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Advantages of Clamp Burning


The burning and cooling of bricks are gradual in clamps. Hence the brick produced are
tough and strong.

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The burning of bricks by clamps is cheap and economical.

No skilled labor and supervision are required.

Not liable to injury from high wind or rain.

There is considerable amount of fuel saving.

Disadvantages of Clamp burning


Bricks are not regular in shape.

Very slow process.

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.

a) Intermittent up-draught kilns

b) Intermittent down-draught kilns

Intermittent up-draught Kilns


In the form of rectangular structures with thick outside walls.

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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.

A temporary roof may be installed of any light material-for protection of bricks.


(roof removed when kiln is fired)

Intermittent up-draught kilns

Intermittent down-draught kilns


These kilns are rectangular or circular in shape.

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.

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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.

There are three types.

Bulls trench kiln

Hoffmans kiln

Tunnel kiln

Bulls Trench Kiln


Invented in England 1876 Commonly used in India, Bull Trench kiln has a permanent
brick chimney over 30 meters high.

The chimney requires skilled labours to construct and is costly to build.

The kiln can only be operated in continuous mode.

It has no roof and can only be used outside the monsoon season.

May be of rectangular, circular or oval shape.

As, the name suggests, it is constructed in a trench excavated in ground.

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It can be fully underground or partially above the ground.

Openings provided in the outer walls- act as flue holes.

Dampers are in the form of iron plates- used to divide the kilns in suitable sections.

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BULLS TRENCH KILN

Hoffmans kiln
Constructed over ground, also known as flame kiln.

Circular in plan and divided into a number of chambers.

As a permanent roof is provided, it can function even in rainy season.

Each chamber is provided with following:

o A main door for loading and unloading of bricks.

o Communicating doors which would act as flues in open condition.

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o A radial flue connected with a central chimney.

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.

o In normal condition, only one radial flue is connected to the chimney to


establish a draught.

o The initial cost of installation is high.

Advantages:

Bricks are burnt


uniformly.

Possible to
regulate the heat
inside.

Can work entire


year as top of
kiln is closed.

Considerable
saving in fuel
due to pre-
heating of raw
bricks

No air pollution
in the locality

Tunnel kiln

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This type of kiln is in the form of tunnel which may be straight, circular or oval in
plan.

It contains a stationary zone of fire.

The raw bricks are placed on trolleys which are then removed from one end to the
other end of tunnel.

The raw bricks get dried and pre-


heated as they approach the zone of
fire.

In zone of fire, the bricks are burnt to


the required degree and they are then
pushed forward for cooling.

When they are sufficiently cooled,


they are unloaded.

This kiln proves to be economical when bricks are to be manufactured on a large scale

As temperature is under control, uniform bricks of better quality are produced.

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TRADITIONAL INDIAN
CLAY BRICK KILN

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BULL TRENCHS BRICK KILN

BRICK CLAMP

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COMPARISON BETWEEN CLAMP-BURNING AND KILN BURNING

QUALITY OF GOOD BRICKS

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FACTORS AFFECTING QUALITY OF BRICKS


Composition of brick earth.

Preparation of clay and blending of ingredients.

Nature of moulding adopted.

Care taken in drying and stacking of raw or green bricks.

Type of kiln used including type of fuel and its feeding.

Burning and cooling processes.

Care taken in unloading.

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.

TESTS FOR BRICKS


A brick is generally subject to following tests to find out its suitability for the
construction work.

1. ABSORPTION

2. CRUSHING STRENGTH

3. HARDNESS

4. PRESENCE OF SOLUBLE SALTS

5. SHAPE & SIZE

6. SOUNDNESS

7. STRUCTURE

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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.

It should not in any case exceed 20% of wt. of dry Bricks.

CRUSHING STRENGTH
Crushing strength of a brick is found out by placing it in a compression testing
machine.

It is pressed till it breaks.

The min. crushing strength of bricks is 55 kg/cm 2 .

HARDNESS
In this test, a scratch is made on brick surface with the help of finger nail.

If no impression is left on the surface, the brick is treated to be sufficiently hard.

SHAPE & SIZE


In this test, a brick is closely inspected. It should be of standard size as per Indian
standards.

Its shape should be truly rectangular with sharp edges.

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.

It is then taken out and allowed to dry in shed.

The absence of grey or white deposits in its surface indicates absence of soluble salts.

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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.

It should be homogeneous, compact and free from any defects

CLASSIFICATION OF BRICKS
Bricks can broadly be divided into two categories.

( i ) Un-burnt or sundried bricks

(ii) Burnt bricks

UN burnt or Sun dried bricks


Un-burnt or sun dried with the help of heat received from sun after the process of
moulding.

These bricks can only be used in the constructions of temporary and cheap structures.

Such bricks should not be used at places exposed to heavy rains.

Burnt Bricks
The bricks used in construction works are burnt bricks and they are classified into the
following four categories.
First Class bricks:

o These bricks are table moulded and of standard shape.

o The surface and edges of the bricks are sharp, square, smooth and straight.

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o They comply all the qualities of good bricks and used for superior work of
permanent nature.

Second class bricks

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.

Third class bricks

o These bricks are ground moulded and they burnt in clamps.

o These bricks are not hard and they have rough surfaces with irregular and
distorted edges.

o These bricks give dull sound when struck together.

o They are used for unimportant and temporary structures and at places where
rainfall is not heavy.

Fourth class bricks

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.

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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.

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