Brick and TileBrick and Tile

One of the oldest building One of the oldest building materialsmaterials

• Manufactured of bricks still follows Manufactured of bricks still follows the same basic proceduresthe same basic procedures

• Modern plants are more efficientModern plants are more efficient

• With complete knowledge of raw With complete knowledge of raw materialsmaterials

• Better kilnsBetter kilns

• Better machineryBetter machinery

Principal Ingredient is clayPrincipal Ingredient is clay

• Must have Must have plasticity when plasticity when mixed with watermixed with water

• Sufficient tensile Sufficient tensile strengthstrength

• Must fuse togetherMust fuse together

Principal Forms of ClayPrincipal Forms of Clay

• Clay occurs in three Clay occurs in three principal forms – same principal forms – same chemical properties – chemical properties – different physical different physical propertiesproperties– Surface clays – found near Surface clays – found near

the surface of the earththe surface of the earth– Shale’s – subjected to high Shale’s – subjected to high

pressures relatively hardpressures relatively hard– Fireclays – deeper levels – Fireclays – deeper levels –

uniform physical and uniform physical and chemical properties – chemical properties – withstand higher temp.withstand higher temp.

ClayClay

• Clay is a complex materialClay is a complex material– Compounds of silica and alumnia and other Compounds of silica and alumnia and other

small ingredientssmall ingredients

• Divided into two classesDivided into two classes– Calcareous ClaysCalcareous Clays

•15 % calcium carbonate – burn a yellowish color15 % calcium carbonate – burn a yellowish color

– Noncalcareous ClaysNoncalcareous Clays•2 to 10% feldspar and iron oxide – reddish color2 to 10% feldspar and iron oxide – reddish color

Manufacturing of Brick and Manufacturing of Brick and TileTile• Mining and StorageMining and Storage

– Mined open pitMined open pit– Clay is in form of large Clay is in form of large

clumps – undergoes clumps – undergoes prelimary crushingprelimary crushing

• Preparing Raw Preparing Raw MaterialMaterial– Crushed into small Crushed into small

pieces no larger then 2 pieces no larger then 2 in.in.

– Grinders reduce it to a Grinders reduce it to a fine powderfine powder

Manufacturing of Brick and Manufacturing of Brick and TileTile• FormingForming

– First step is tempering (adding water)First step is tempering (adding water)– Amount of water depends on methodAmount of water depends on method

• Stiff mud process – only enough water Stiff mud process – only enough water to produce plasticity (12 to 15%)to produce plasticity (12 to 15%)

– Clay forced into a die producing a Clay forced into a die producing a continuous column of clay of proper continuous column of clay of proper size and shape then cut to sizesize and shape then cut to size

• Soft mud process (20 to 30% water)Soft mud process (20 to 30% water)– Clays which contain to much natural Clays which contain to much natural

waterwater– Clay is placed into moldsClay is placed into molds– Oldest method of brick makingOldest method of brick making

• Dry press process (-10% water)Dry press process (-10% water)– Clay is placed into molds under high Clay is placed into molds under high

pressurepressure

Manufacturing of Brick and Manufacturing of Brick and TileTile

• DryingDrying– Before drying must have between 7 to Before drying must have between 7 to

30% water30% water– Kilns are used to dryKilns are used to dry– Shrinkage occursShrinkage occurs– Temp range from 28 to 204 degrees CTemp range from 28 to 204 degrees C– Drying time ranges from 24 to 48 hoursDrying time ranges from 24 to 48 hours

Manufacturing of Brick and Manufacturing of Brick and TileTile• GlazingGlazing

– Gives glass like coatingGives glass like coating

• Burning and Cooling 40 to 150 hBurning and Cooling 40 to 150 h– Water smoking – evaporation of free water 204 Water smoking – evaporation of free water 204

CC– Dehydration – removal of all water 149 – 982 CDehydration – removal of all water 149 – 982 C– Oxidation – 538 – 932 COxidation – 538 – 932 C– Virtirification – 871 – 1315 CVirtirification – 871 – 1315 C

• Storing and ShippingStoring and Shipping

Brick SizesBrick Sizes

• 4 in. building module4 in. building module

• Standard Imperial – nominal size of 4 Standard Imperial – nominal size of 4 x 2 ¼ x 8 in – actual 3 5/8 x 2 1/16 x x 2 ¼ x 8 in – actual 3 5/8 x 2 1/16 x 7 1/27 1/2

Common BricksCommon Bricks

• Comes in 3 gradesComes in 3 grades– SW – wet conditions – SW – wet conditions –

high resistance to frost high resistance to frost action compression action compression strength rating of 3000 strength rating of 3000 psipsi

– MW – dry conditions – MW – dry conditions – low resistance to frost – low resistance to frost – 2500 psi2500 psi

– NW – back up interior – NW – back up interior – no freezing – 1500 psino freezing – 1500 psi

• Two common designsTwo common designs– Wire cut – 8 holesWire cut – 8 holes– Pressed – 3 holesPressed – 3 holes

MortarMortar

• Joints are ½ or 3/8 in. sizeJoints are ½ or 3/8 in. size• TypesTypes

– Type M – General use – use below gradeType M – General use – use below grade• 1 part portland cement, ¼ part hydrated lime, 3 parts sand1 part portland cement, ¼ part hydrated lime, 3 parts sand

– Type S – General purpose mortar bond high Type S – General purpose mortar bond high resistance to lateral forceresistance to lateral force• 1 part portland cement, ½ part hydrated lime, 4 ½ parts 1 part portland cement, ½ part hydrated lime, 4 ½ parts

sandsand– Type N – Exposed masonry above gradeType N – Exposed masonry above grade

• 1 part portland cement, 1 part hydrated lime, 6 parts sand1 part portland cement, 1 part hydrated lime, 6 parts sand– Type O –Less then 100 psi – no freeze or thawType O –Less then 100 psi – no freeze or thaw

• 1 part portland cement, 2 parts hydrated lime, 9 parts 1 part portland cement, 2 parts hydrated lime, 9 parts sandsand