Lecture 2 brick,brick masonary and manufacturing of bricks

76
Materials and Method of Construction Brick, Brick Masonry Manufacturing of Bricks Munawar Hussain Civil Engineering Department MNS-University of Engineering and Technology Multan

Transcript of Lecture 2 brick,brick masonary and manufacturing of bricks

Page 1: Lecture 2 brick,brick masonary and manufacturing of bricks

Materials and Method of Construction

Brick, Brick Masonry Manufacturing of Bricks

Munawar HussainCivil Engineering DepartmentMNS-University of Engineering and Technology Multan

Page 2: Lecture 2 brick,brick masonary and manufacturing of bricks

BRICK MASONRYThe art of building structures using bricks and binding materials like cement (mortar) is called brick masonry.

STONE MASONRYThe art of building structures using stones and binding materials like cement (mortar) is called stone masonry.

BLOCK MASONRYThe art of building structures using concrete blocks with binding materials like cement (mortar) is called block masonry.

Page 3: Lecture 2 brick,brick masonary and manufacturing of bricks

Basic Terms of Brick

1. Header2. Stretcher

Brick is a basic building unit which is in the form of rectangular block.Standard size (Normal size) 9'' ×4½" ×3"

or (225 mm x112 mmx 75 mm)

Page 4: Lecture 2 brick,brick masonary and manufacturing of bricks

Basics Terms• Arises

The edges formed by the intersection of plane surfaces of a brick are called arises.

• FrogThe depression provided in the face of a brick during its manufacturing is called the frog.

• CourseEach horizontal layer of bricks laid in mortar is called course.

Arises

Frog

Courses

Page 5: Lecture 2 brick,brick masonary and manufacturing of bricks

QuoinsThe external corners of a wall are called Quoins. And the bricks forming quoins are called quoin bricks. e.g. quoin header or quoins stretcher.

PerpendsThe vertical joints of the bricks are called Perpends. The perpends of the alternate courses should be in the same vertical line

Perpends

Quoin Header

Quoin Stretcher

Basic Terms

Page 6: Lecture 2 brick,brick masonary and manufacturing of bricks

Basic Terms

JambsIt is the vertical sides of door or window opening to which the door is or window frame is attached.

SoffitThe under surface of any structural member such as a lintel, a slab is called Soffit.

SillThe horizontal surface at the bottom side of a door or window opening is called sill.

Page 7: Lecture 2 brick,brick masonary and manufacturing of bricks

Mortar The mixture of binding material and fine aggregate forming a workable past is called mortar.

Grout or slurryThe thin paste of cement is called grout or slurry. It is used to fill the joints.

LintelA small horizontal member to span up small opening is called lintel.

Page 8: Lecture 2 brick,brick masonary and manufacturing of bricks

Types of Closer : King Closer

Page 9: Lecture 2 brick,brick masonary and manufacturing of bricks

Types of Closer : Queen Closer

1/2

1/2

Page 10: Lecture 2 brick,brick masonary and manufacturing of bricks

Types of Closer : Mitred Closer

Angle 45° to 60°

Page 11: Lecture 2 brick,brick masonary and manufacturing of bricks

Types of Closer : Bevelled Closer

1/2

Page 12: Lecture 2 brick,brick masonary and manufacturing of bricks

Bat 1/2

1/2

Page 13: Lecture 2 brick,brick masonary and manufacturing of bricks

Bat 3/4

3/4

Page 14: Lecture 2 brick,brick masonary and manufacturing of bricks

Bevelled Bat

Page 15: Lecture 2 brick,brick masonary and manufacturing of bricks

Types of Bond

Stretcher Bond

Header Bond

English Bond

Flemish Bond

Page 16: Lecture 2 brick,brick masonary and manufacturing of bricks

Stretcher Bond

Page 17: Lecture 2 brick,brick masonary and manufacturing of bricks

Header Bond

Page 18: Lecture 2 brick,brick masonary and manufacturing of bricks

English Bond

Page 19: Lecture 2 brick,brick masonary and manufacturing of bricks

Flemish Bond

Page 20: Lecture 2 brick,brick masonary and manufacturing of bricks

Corner Junctions (English Bond & Flemish Bond)

Page 21: Lecture 2 brick,brick masonary and manufacturing of bricks

Tee Junctions (English Bond & Flemish Bond)

Page 22: Lecture 2 brick,brick masonary and manufacturing of bricks

Cross Junction & Squint Junctions

Page 23: Lecture 2 brick,brick masonary and manufacturing of bricks

Test for Bricks

A brick is generally subjected to the following tests to find for the construction work,

(1) Absorption(2) Crushing strength(3) Hardness(4) Presence of soluble salts(5) Shape and size(6) Soundness(7) Structure

Page 24: Lecture 2 brick,brick masonary and manufacturing of bricks

1) Absorption:

A brick is taken and it is weighed dry. It is then immersed in water for a period of 16 hours. It is weighed again and the difference in weight indicates the amount of water absorbed by the brick. It should not in exceed 20 per cent of weight of dry brick.

Page 25: Lecture 2 brick,brick masonary and manufacturing of bricks

(2)  Compressive/Crushing strength of Bricks:

The crushing strength of a brick is found out by placing it in a compression testing machine. It is pressed till it breaks.

The minimum crushing or compressive strength of bricks is 3.50 N/mm2.

Page 26: Lecture 2 brick,brick masonary and manufacturing of bricks

(3) Hardness test on bricks:

In this test, a scratch is made on brick surface with the help of a finger nail. If no impression is left on the surface, the brick is sufficiently hard.

Page 27: Lecture 2 brick,brick masonary and manufacturing of bricks

(4) Presence of soluble salts:1) The soluble salts, cause

efflorescence on the surface of bricks.

2) For finding out the presence of soluble salts in a brick, it is immersed in water for 24 hours. It is then taken out and allowed to dry in shade.

3) The Presence of white deposits on indicates presence of soluble salts.

Page 28: Lecture 2 brick,brick masonary and manufacturing of bricks

(4) Presence of soluble salts:

Page 29: Lecture 2 brick,brick masonary and manufacturing of bricks

(5) Shape and size:1) In this test, a brick is closely inspected. It should be of standard size

and its shape should be truly rectangular with sharp edges. 2) For this purpose, 20 bricks of standard size (225 mm x 112.5 mm x 75

mm) are selected at random and they are stacked lengthwise, along the width and along the height.

3) For good quality bricks, the results should be within the following permissible limits

Page 30: Lecture 2 brick,brick masonary and manufacturing of bricks

(6) Soundness test on brick:

In this test, the two bricks are taken and they are struck with each other. The bricks should not break and a clear ringing sound should be produced.

Page 31: Lecture 2 brick,brick masonary and manufacturing of bricks

(7) Structure of a brick:

A brick is broken and its structure is examined. It should be homogeneous, compact and free from any defects such as holes, lumps, etc.

Page 32: Lecture 2 brick,brick masonary and manufacturing of bricks

Classification of BricksThe classification of bricks is as follows:

(i)unburnt or sun-dried bricks; and (ii)burnt bricks.

The unburnt or sun-dried bricks are those bricks • which are  dried with the help of heat

that is received from sun after the process of moulding.

• The unburnt bricks can only be used in the construction of  simple temporary and cheap structures.

• Unburnt bricks should not be used at places exposed to heavy rains

Page 33: Lecture 2 brick,brick masonary and manufacturing of bricks

Classification of Burnt Bricks

The bricks used in construction works are burnt bricks and they are classified into the following four categories:

(1) First class bricks(2) Second class bricks(3) Third class bricks(4) Fourth class bricks

Page 34: Lecture 2 brick,brick masonary and manufacturing of bricks

First class bricks: 

Specifications: (1) Plain surface, sharp edges and size with tolerance in dimensions +3%(2) Uniform red or brownish colored.(3) High crushing strength, not less than 10.7 N/mm2

(4) Machine moulded(5) Efflorescence- NIL(6) Water absorption less than 15%.

USE: They are used for the exterior wall brick works, short columns and arches.

Page 35: Lecture 2 brick,brick masonary and manufacturing of bricks

Second class bricks:

Specifications:(1) Slightly uneven faces and edges with tolerance in dimensions +8%(2) Uniform colored but may be slightly over burnt.(3) High crushing strength, not less than 7 N/mm2(4) Hand moulded(5) Efflorescence-Little(6) Water absorption less than 20%.

USE: They are used for internal walls and compound walls.

Page 36: Lecture 2 brick,brick masonary and manufacturing of bricks

Third class bricks:

Specifications:(1) May be distorted with blunt edges.(2) Over burnt or under burnt and non-uniform color.(3) Crushing strength, not less than 3.5N/mm2(4) Hand moulded(5) Efflorescence- Large(6) Water absorption less than 25%.

USES: They are used for flooring, paving, small brick foundations and brick blast.

Page 37: Lecture 2 brick,brick masonary and manufacturing of bricks

1) These are overburnt bricks with irregular shape and dark colour.

2) These bricks are used as aggregate for concrete in foundations, brick floors, surkhi, roads, etc. because of the fact that the overburnt bricks have a compact structure and hence they are sometimes found to be stronger than even the first class bricks.

3) It is thus seen that the above classification of bricks is based on the of manufacturing or preparing bricks.

Fourth class bricks:

Page 38: Lecture 2 brick,brick masonary and manufacturing of bricks

Classification based on shapeThe ordinary bricks are rectangular solids. But sometimes the bricks are given different shapes to make them suitable for particular type of construction. Here we have enlisted different types of bricks available with various shapes:

Bullnose brick: 1. A brick moulded with a rounded angle is termed as a bullnose. 2. This type of brick is used for a rounded quoin.

Page 39: Lecture 2 brick,brick masonary and manufacturing of bricks

Channel bricks: 1. These types of bricks are moulded to the shape of a

gutter or a channel and they are often glazed.2. These bricks are used to function as drains..

Page 40: Lecture 2 brick,brick masonary and manufacturing of bricks

Coping bricks: It is provided at the top of a wall to avoid dampness. They are specially designed bricks to cover the tops of brick parapet walls.These bricks are made to suit the thickness of walls on which coping is to be provided.

Page 41: Lecture 2 brick,brick masonary and manufacturing of bricks

Hollow bricks:1. They are light in weight about one-third the weight of the

ordinary brick of the same size. 2. These bricks leads to speedy construction. 3. They also reduce the transmission of heat, sound and

damp.

Page 42: Lecture 2 brick,brick masonary and manufacturing of bricks

Paving bricks: 1. These bricks are prepared from clay containing a higher

percentage of iron. 2. Such bricks resist better the abrasive action of traffic. 3. The paving bricks may be plain or chequered.4. These bricks are extensively used for garden walks,

street pavements, stable floors, etc. These types of bricks also render the floor less slippery.

Page 43: Lecture 2 brick,brick masonary and manufacturing of bricks

Perforated bricks: 1. These bricks contain cylindrical holes throughout their

thickness. 2. These bricks are light in weight and they require less

quantity of clay for their preparation. 3. The drying and burning of these bricks are also easy. 4. They may be of different shapes like circular, square

rectangular or any other regular shape in cross-section. 5. The compressive strength of perforated bricks should not be

less than 7 N/mm2 .

Page 44: Lecture 2 brick,brick masonary and manufacturing of bricks

Purpose-made bricks: 1. In order to achieve certain purpose, these types of bricks are

made. 2. Engineering bricks are prepared for constructions where high

durability, compression strength and adequate resistance to sudden shocks are required.

3. These types of bricks are usually more costly than the ordinary bricks. But they grant safe, clean and quick construction.

Page 45: Lecture 2 brick,brick masonary and manufacturing of bricks

Masons tools in Bick masonry

• Trowel• Brick hammer• Lines and pins• Spirit level and water level• Straight edge• Plumb Line• Mason’s square (guniya)• Tape (steel)

Page 46: Lecture 2 brick,brick masonary and manufacturing of bricks

Mason’s Tools

Page 47: Lecture 2 brick,brick masonary and manufacturing of bricks

Use of Trowel & Lines and Pins

Page 48: Lecture 2 brick,brick masonary and manufacturing of bricks

Use of Plumb bob and Edge

Page 49: Lecture 2 brick,brick masonary and manufacturing of bricks

MANUFACTURING OF BRICKS

Page 50: Lecture 2 brick,brick masonary and manufacturing of bricks

Clay BricksManufactured from clay. The basic compositions of clay brick are:

i. Silica (SiO2) – 60%ii. Alumina (Clay) (Al2O3) – 20%iii. Remaining ingredients – 20%

• Remaining ingredients such as: i. Calcium oxide (Lime)ii. Iron oxide – give red colouriii. Manganeseiv. Magnesium oxide

Page 51: Lecture 2 brick,brick masonary and manufacturing of bricks

Functions of Ingredients• Silica – Free silica (sand), if added to clay in suitable

proportion makes a brick hard and prevents it from warping and shrinking on drying.

• Alumina – Alumina is main constituent of every clay. On the addition of water clay becomes plastic and can be moulded into shape.

• Lime – It helps to lower the fusion temperature, i.e. it helps silica to fuse at lower temperature and thus helps to bind the particle together. It also prevents shrinkage of raw bricks

Page 52: Lecture 2 brick,brick masonary and manufacturing of bricks

Harmful ingredients• Alkalise – Lower the fusion temperature and melts the

brick, changes it shape or get twisted. Also these salts have hygroscopic action.

• Iron pyrites – During burning, iron pyrites due to high temperature oxidise, decompose and disintegrate brick into pieces.

• Organic matter –Although the presence of organic matter in brick helps it burning, this causes porosity in the bricks. The presence of organic matter such as roots, dry leaves, in brick should be avoided. 

Page 53: Lecture 2 brick,brick masonary and manufacturing of bricks

MANUFACTURING OF BRICKS

1. Preparation of brick earth

2. Moulding of bricks

3. Drying of bricks

4. Burning of bricks

Page 54: Lecture 2 brick,brick masonary and manufacturing of bricks

Removal of loose soilThe top layer of the loose soil about 30 cm depth contains a lot of impurities like organic matter and hence it should be taken out and thrown away.

Digging, spreading and cleaningThe earth is then dug out from the ground. This earth is spread into heapsabout 50 to 150 cm height.

WeatheringThe earth is then exposed to atmosphere for softening. The period may be of few weeks to a season.

Blending and temperingThe clay is then mixed with suitable ingredients. It is carried out by taking a small portion of clay every time and by turning it up and down in vertical direction (Pug Mill).

MANUFACTURING OF BRICKS

Page 55: Lecture 2 brick,brick masonary and manufacturing of bricks

MATERIAL PREPARATION

Page 56: Lecture 2 brick,brick masonary and manufacturing of bricks

Pug Mill

Page 57: Lecture 2 brick,brick masonary and manufacturing of bricks

MOULDING

Hand mouldingWhen moulding is done with hand it is called hand moulding. A wooden rectangular mould made in the shape of a brick is

normally used for this purpose.

Machine mouldingThe clay is placed in the machine, it comes out through the opening

under pressure. It is cut to bricks by steel wires fixed into frames.

Page 58: Lecture 2 brick,brick masonary and manufacturing of bricks

DRYING OF BRICKS

• Wet brick from molding or cutting machines contain 7 to 30 percent moisture, depending upon the forming method.

• Before the firing process begins, most of this water is evaporated in dryer chambers at temperatures ranging from about 100 ºF to 400 ºF (38 ºC to 204 ºC).

• The extent of drying time, which varies with different clays, usually is between 24 to 48 hours.

• Heat and humidity must be carefully regulated to avoid cracking in the brick.

Page 59: Lecture 2 brick,brick masonary and manufacturing of bricks

BURNING OF BRICKS(A) INTERMITTENT KILN - CLAMP , SCOVE(Loading, unloading, Cooling, and Burning of bricks)Highly inefficient & labor-intensive.Most common, most pollutingTemporary Structures

A typical scove kiln.

Page 60: Lecture 2 brick,brick masonary and manufacturing of bricks

(B) CONTINOUS KILN BURNING (HOFFMAN, BULL’S TRENCH, VERTICAL SHAFT ) These are permanent structures. Burning is done continuously in kilns.Bricks from kilns are of correct size, perfect shape and good quality.Rate of burning is also high in kilns.But initial investment for kiln is very high.

There are two well-known continuous kilns:

1. BULL’S TRENCH Kiln 2. Hoffman Kiln

Page 61: Lecture 2 brick,brick masonary and manufacturing of bricks

BULL’S TRENCH KILN Bull's trench kiln consist of a rectangular, circular or oval plan shape. They are constructed below the ground level by excavating a trench of the required width for the given capacity of brick manufacturing.

This Trench is divided generally in 12 chambers so that 2 numbers of cycles of brick burning can take place at the same time for the larger production of the bricks. Once fire is started it constantly travels from one chamber to the other chamber, while other operations like loading, unloading, cooling, burning and preheating taking place simultaneously.

Its manufacturing capacity of about 20,000 bricks per day.

Page 62: Lecture 2 brick,brick masonary and manufacturing of bricks

BULL’S TRENCH KILN Used in India, Pakistan, Nepal, Bangladesh

“Movable chimney” (MC) and “Fixed” Fixed (FC)

MCBTK banned (but still used) in India, parts of Nepal & Pakistan due to very high emissions

Page 63: Lecture 2 brick,brick masonary and manufacturing of bricks

The main difference between the Bull's trench kiln and the Hoffman kilns are:1.Hoffman's kiln is an over the ground structure while

Bull's Trench Kiln is an underground structure.2.Hoffman's kiln have a permanent roof while Bull's

trench Kiln do not have so it former can be used in 12 months a year to manufacture bricks but later is stopped in the monsoon season.

Hoffman's kiln is generally circular in plan, and is constructed over the ground. The whole structure is divided into the 12 chambers and all the processes takes place simultaneously like in Bull's trench Kiln.

HOFFMANN KILN

Page 64: Lecture 2 brick,brick masonary and manufacturing of bricks

HOFFMANN KILN – ORIGINAL

Page 65: Lecture 2 brick,brick masonary and manufacturing of bricks

HOFFMANN KILN – MODERN & HYBRID Widely used in China= 90% of bricks Can use coal ornatural gas

Page 66: Lecture 2 brick,brick masonary and manufacturing of bricks

Loaded at top, bricks removed from bottom• High efficiency, low emissions• Kiln of choice for aid agencies India, Nepal, Pakistan, Vietnam

VERTICAL SHAFT BRICK KILN (VSBK)

Page 67: Lecture 2 brick,brick masonary and manufacturing of bricks

Reinforced brick Masonry•The brick masonry done by embedding reinforcement in rich cement mortar is called Reinforced brick masonry.

•Reinforcement used may be in the form of• Steel bars• Hoop iron• Wire mesh

Page 68: Lecture 2 brick,brick masonary and manufacturing of bricks

Reinforced Brick Masonry

Page 69: Lecture 2 brick,brick masonary and manufacturing of bricks

Constructions of Brick Masonry

• It is the art of laying bricks in a proper bond with specified mortar to form a structure.

It involves the following activities…• Selection of bricks• Stacking of bricks• Soaking of bricks• Preparation of mortar (ASTM Specifications C 270, "Mortar for Unit Masonry“)

• Laying of bricks

Page 70: Lecture 2 brick,brick masonary and manufacturing of bricks

General Principles and precautions in Brick Masonry

• English bond should be used if not specified.• Bricks used should be well burnt and should be uniform

in size, shape and colour.• For facing work selected bricks should be used.• Curing of bricks should be done for at least 2 hours.• Bricks should be laid with frogs pointing upward or as

specified by the Engineer In charge.• Mortar used in brick masonry should be of good quality.• Brick bats are avoided.

Page 71: Lecture 2 brick,brick masonary and manufacturing of bricks
Page 72: Lecture 2 brick,brick masonary and manufacturing of bricks
Page 73: Lecture 2 brick,brick masonary and manufacturing of bricks

Piers of Bricks

Page 74: Lecture 2 brick,brick masonary and manufacturing of bricks

A cornice is any horizontal decorative molding that crowns a building.

Frieze any decorative band on an outside wall, bearing lettering or sculpture etc.

Page 75: Lecture 2 brick,brick masonary and manufacturing of bricks

Advantages of Brick

1.Brick will not burn, buckle or melt.2.Brick will not rust and corrode.3.Brick will not require constant maintenance.4.Economical (Raw material is easily available)5.Hard and durable6.Compressive strength is good enough for ordinary

construction7.Different orientations and sizes give different surface

textures8.Reusable and Recyclable9.Highly fire resistant

Page 76: Lecture 2 brick,brick masonary and manufacturing of bricks

Disadvantages of Bricks1. Time consuming construction2. Cannot be used in high seismic zones3. Since bricks absorb water easily, therefore, it causes

fluorescence4. Very Less tensile strength5. Cleaning brick surfaces is a hard job6. Color of low quality brick changes when exposed to

sun for a long period of time