Different types of bricks are used in masonry construction based on material such as

clay, concrete, lime, fly ash etc. Filed field identification of bricks for their
properties, uses and suitability for different construction works are important.

A brick is an important construction material which is generally available in

rectangular shape manufactured from clay. They are very popular from olden days
to modern days because of low cost and durability.

Types of Bricks used in Masonry Construction

Based on the manufacturing process, bricks are broadly classified into two types, 1.
Sun-Dried or unburnt bricks 2. Burnt bricks

1. Sun-Dried or Unburnt Clay Bricks

Sun-dried or unburnt bricks are less durable and these are used for temporary
structures. Unburnt bricks preparation involved in 3 steps they are preparation of
clay, molding and drying.

After molding, bricks are subjected to sunlight and dried using heat from sun. So,
they are not that much strong and they also have less water resistance and less fire
resistance. These bricks are not suitable for permanent structures.

2. Burnt Clay Bricks

Burnt bricks are good quality bricks but however they also consist some defected
bricks. They have high strength as compared to unburnt bricks. So, burnt bricks are
classified into four types and they are

o First class bricks

o Second class bricks
o Third class bricks
o Fourth class bricks
o
First Class Bricks
First class bricks are good quality bricks compared to other classes. They are molded
by table-molding and burnt in large kilns. So, these bricks contain standard shape,
sharp edges and smooth surfaces.

They are more durable and having more strength. They can be used for permanent
structures. However, because of their good properties they are costly than other
classes
These are 19 x 9 x 9 cm in size. They are made from good earth, free from saline
deposits. They should be thoroughly burnt.
They should be of good color. They should be of regular shape with square edges
and parallel faces.
These bricks are free from flaws, cracks, chips, stones, etc. They should give a
ringing sound when two bricks are struck together.
Its compressive strength shall not be less than 140 kg/cm2. And they shall not absorb
more than 20% of water when immersed in water for 24 hours.
USE: Excellent for all types of construction in the exterior walls. They are also
suitable for flooring.

Second Class Bricks

Second class bricks are moderate quality bricks and they are molded by ground-
molding process. These bricks are also burnt in kilns. But because of ground
molding, they do not have smooth surfaces as well as sharp edges.

The shape of bricks also irregular due to unevenness in ground. These also will give
best results in strength and durability. Smooth plastering is required on the brick
structure. Second class bricks are also fully burnt and give a clear ringing sound
when struck together. Slightly irregularities in shape, size or color are accepted.
Its compressive strength shall not be less than 70 kg/cm2, and absorption value
should not be greater than 22 percent when soaked for 24 hours in water.
Slight difference in the structure on fractured surfaces is admissible.
Use: For exterior work when plastering is to be done. And can also be used for
interior works but they may not be used for flooring.

Third Class Bricks

Third class bricks are poor quality bricks which are generally used for temporary
structures like unburnt bricks. These are not suitable for rainy areas. They are
ground-molded type bricks and burnt in clamps. The surface of this type of bricks
are rough and they have unfair edges

These are not burnt so fully as in previous two cases but are generally of uniform
reddish yellow color.
Defects in uniformity or shape are tolerated. On striking together, they produce a
dull thud sound.
Its compressive strength lies between 35 – 70 kg/cm2 and absorption between 22 –
25 percent.
Use: They are used mostly in the ordinary type of construction and in dry situations .

.
Fourth Class Bricks

Fourth class bricks are very poor quality bricks and these are not used as bricks in
the structure. They are crushed and used as aggregates in the manufacturing of
concrete. They are obtained by over burning, because of this they gets overheated
and obtains brittle nature. So, they can break easily and not suitable for construction
purpose

These types of bricks are irregular in shape and dark in color which is due to
overburning.
They are quite strong in compressive strength, generally above 150 kg/cm2 and low
in porosity and absorption.
Use: Despite their high strength, these types of bricks are unfit for use in building
construction. This is because of their distorted shape and irregular size.
They are, however, very commonly used in a
broken form, in road construction, foundations and floors as a coarse
aggregate material.

3. Fly Ash Bricks

Fly ash bricks are manufactured using fly ash and water. These bricks have better
properties than clay bricks and great resistant to freeze thaw cycles. These bricks
contains high concentration of calcium oxide which is used in cement production,
thus it is also called as self-cementing brick. Fly ash bricks are lightweight and thus
it reduces self weight of structures.

The advantages of fly ash bricks over clay bricks are that they have high fire
insulation, high strength, uniform sizes for better joints and plaster, lower water
penetration, does not require soaking before use in masonry construction.

4. Concrete Bricks
 Concrete bricks are manufacturing using concrete with ingredients as cement, sand,
coarse aggregates and water. These bricks can be manufactured in sizes as required.

The advantages of using concrete bricks over clay bricks are that they can be
manufactured at construction site, reduces quantity of mortar required, can be
manufactured to provide different colors as pigmented during its production.

Concrete bricks are used for construction of masonry and framed buildings, facades,
fences, and provide an excellent aesthetic presence.

5. Engineering Bricks
Engineering bricks have high compressive strength and are used special applications
where strength, frost resistance, acid resistance, low porosity is required. These
bricks are commonly used for basements where chemical or water attacks are
prevalent and for damp proof courses.

6. Sand Lime or Calcium Silicate Bricks

Calcium silicate bricks are made of sand and lime and popularly known as sand lime
bricks. These bricks are used for several purposes in construction industries such as
ornamental works in buildings, masonry works etc.

Identification of Bricks Quality at Construction Site

To build a good quality structure, observing quality of materials is important. Here
we discuss about how good bricks are identified at construction site.

o The color of bricks should be bright and uniform.

o They should be well burned and having smooth surfaces and sharp edges.
o Thermal conductivity of bricks should be less and they should be sound proof.
o They shouldn’t absorb more than 20% by weight when we placed it in water.
o When we struck two bricks together, ringing sound should be delivered.
o Structure of bricks should be homogeneous and uniform.
o The bricks should not break when we dropped it form 1m height.
o There should not be any scratch left on the brick when we scratched with finger nail.
o There should not be any white deposits on brick, when we soaked it in water for 24
hrs.
o
 Properties of Bricks
Following are the properties of bricks which represents the importance of bricks in
construction. i. Hardness ii. Compressive strength iii. Absorption

Hardness of Bricks
A good quality brick will have resistance against abrasion. This property is called
hardness of brick which helps to give permanent nature of brick structure. Because
of this property bricks do not damaged by scraping.

Compressive strength of Bricks

Compressive strength or crushing strength is the property of brick which represent
the amount of load carried by brick per unit area. According to BIS the minimum
compressive strength of brick should be 3.5N/mm2. Crushing strength of bricks
reduced when they are soaked in water.

Crushing strength of Bricks Grades

7 – 14 N/mm2 Class A

>14N/mm2 Class AA

Absorption of Bricks
Bricks are generally absorbs water but having limits. Absorption limit percentage by
weight for different classes of bricks is tabulated below.

Class of Bricks Water Absorption % by weight

Heavy duty bricks (special made) Only 5%

First class 20%

Second class 22%

Third class 25%

Uses of Different Types of Bricks

Bricks are widely used in construction industry for different purposes as following.

o Good quality bricks (1st and 2nd class) are used in the construction of buildings,
tunnels, pitching works etc.
o 3rd class and unburnt bricks are used for temporary structures.
o 4th class bricks are used as aggregate for making concrete.
o Bricks are also used for architectural purposes to give aesthetic appearance to the
structure.

Classification of Bricks Based on Modification in Shape.

o In construction, there are positions where a perfect rectangular shape brick will not
be suitable. It has to be modified.
o Such bricks are required in the plinth, the corners of the walls and at the copings.
o There is a long list of such Special-Shaped bricks… We will discuss the important
ones here.
o i. Squint Brick:
o They are cut on one corner at an angle of other than 90 degrees. They are required
for giving shape to an exterior or interior corner in a wall.
o ii. Splay or Can Brick:
o These have a level or portion taken off, width wise, length wise, or in both directions.
The various shapes grouped under splay bricks are made for use in jambs of doors
and windows and also in plinths.
o iii. Coping Bricks:
o They are used for coping on walls in order to give them a nice appearance and also
for easy drainage of water.
o When a coping is to be provided to a wall, a special shape may be desired. The
chamfered, the half round, and the saddleback bricks are some common coping
bricks.
o iv. Bullnose:
o Bullnose bricks are used at turns of the wall so that round corners are obtained. It is
a standard brick having one edge rounded.
o
 o

o v. Cownose:
o It is similar to bullnose, but it has both edges rounded on one side. It may also be
called double bullnose bricks. They have the same use as bullnose, but they just give
additional roundness.
o Classification of Bricks based on Cavities:
o Three types of bricks shall be discussed under this category.
o i. Perforated Bricks:
o These form a modem class of building bricks that have many advantages over the
ordinary solid brick.
o In perforated bricks, cylindrical, rounded or rectangular holes are made in the bricks
after the molding stage. These holes are called perforations.
o They are properly spaced from the side of the brick, and the minimum distance is 15
mm. Further, a distance between any two perforations is not less than 10 mm.
o The volume of the perforations may be as much as 20 – 50 percent of the total
volume of the brick.
o They may be larger in size than ordinary building brick which is a distinct advantage
in that work output of a Mason will increase considerably with the use of perforated
bricks.

o
o The major advantages that perforated bricks offer over ordinary bricks are:
o (i) They are light in weight.
o (ii) Less quantity of clay is required for their manufacture.
o (iii) Less time is required for drying and burning of perforated bricks.
o (iv) These offer better resistance against rain penetration and better insulation
against heat. As such they are ideally suited for tropical countries.
o (v) Efflorescence is least in perforated bricks.
(vi) These are especially suitable for the construction of brick panels in multi-story
structures.
o Perforated bricks have as yet to find popularity in all countries although they are
already widely used in Germany, France, and America.
o Already there is a trend for their use.
o The manufacture of perforated bricks requires slightly sophisticated technology, and
that is the main reason for lesser use in all over the world.
o ii. Hollow Bricks:
o Hollow bricks also called cavity bricks or cellular bricks they have well-defined sets
of cavities with specified dimensions made in the body of the brick.
o As a result, their net weight may be only one-third to one-half of the solid portion. It
is important that the thickness of the brick wall near the cavity should not be less
than 2 cm.
o The hollow bricks are made from a special type of brick clay (which should have
higher clay content).
o They offer the following advantages over the ordinary types of bricks.
o (i) Being light in weight, they can be handled more conveniently, and the output of
the mason may be three to four times compared to ordinary bricks.
o (ii) They offer better insulation against heat and sound.
o (iii) They are ideal and economical for non-load-bearing walls, e.g., in partition
walls.
 o

o iii. Channel OR Gutter Bricks:

o They are actually special purpose bricks baring a continuous central semi-circular
cavity or depression running through their length.
o Very often they are glazed to make them impervious: They are mostly used in the
laying of drains.

o Classification of Bricks Based on Composition:

o We will discuss 2 major classification of bricks here below.
o i. Sand LIME Bricks:
o Definition. These are building bricks made from sand and lime as the raw materials
instead of clay. The clay content may be only negligible.
o They differ from ordinary clay bricks not only in composition but also in the method
of manufacture. They are, however, similar in shape and size to the ordinary types
of bricks.
o Manufacture. The principal raw materials for sand-lime bricks are:
o (1) Sand. It must be free from harmful impurities like chloride, iron oxides, black
minerals and organic matter. Sand forms around 90 percent of sand-lime bricks.
o (ii) Lime. It is used in the form of a slaked (hydrated) lime. Its content varies from
8-12 percent.
o The slaked lime used for brick making has high calcium-content and should be free
from magnesium.
o Besides the two essential components, some clay (up to four percent) in finely
divided form is desirable. Pure, salt-free water (not sea water) is another
requirement.
o For giving a required color to the sand-lime bricks, some pigments are added in small
percentages to the ingredients at the mixing stage.
o Among these pigments, the following are used Commonly;
o Iron-oxides for red and brown color.
o Chromium Oxide for green color.
o Ochre for yellow color.
o Carbon black for Grey and black color.
o Molding. After mixing the finely powdered raw materials in the desired proportion,
a damp mixture is obtained adding 2-3 per cent clean water.
o From this damp mixture, brick-shaped units are molded using ROTARY PRESS.
Pressures applied range from 300-600 kg/cm2.
o Such high-pressure results in highly compressed and dense sand-lime bricks which
are almost dry at this stage.
o Autoclaving. The molded units are put into an autoclave (a steel cylinder with the
closed end where heating is done by steam under pressure).
o In the autoclave, the bricks are treated for 6-12 hours under steam pressures between
8-16 kg/cm2
o It is in the autoclave that sand and lime react chemically and form a chemical
compound, calcium-silicate. That is the chemical composition of the sand-lime
brick.
o The sand-lime bricks taken out from the autoclave are ready for use.
 o

o Properties of Sand Lime Bricks.

o (i) The sand-lime bricks have a very smooth and uniform finish and a pleasing
appearance.
o (ii) They are quite dense, strong and hard.
o (iii) They are least porous and hence free from efflorescence.
o Because of these properties, sand-lime bricks offer many advantages.
o (i) They are uniform in shape, size and finish and hence require no plastering.
o (ii) The quantity of plaster when required is quite less because of the smooth surface
of the brick.
o (iii) They are water repelling and hence free from absorption related defects of
ordinary bricks.
o (iv) Since the materials required for sand-lime bricks are also quite common in
occurrence, these can provide a suitable alternative to clay-bricks.
o We should know that most clay used in making bricks is from agricultural lands and
hence its conservation will help in increasing food production.
o Among the major disadvantages of sand-lime bricks, the following may be
mentioned:
o (i) They can be manufactured only by using mechanized methods. Hence their
production at village levels is almost impossible at present.
o (ii) They are unsuitable for foundations and paving uses. In the first case, they get
damaged in the presence of water, and in the second case, it is because they have
poor resistance to abrasion.
o The Scope of Use. In Western countries, sand-lime bricks are used quite widely.
Sooner or later, they will have to be introduced in other countries too on a large
scale.
o ii. Fire OR Refractory BRICKS:
o Definition. This is a separate group of bricks which is capable of withstanding in
very high temperatures without undergoing any deformation in shape or size and
without reacting with the material of a particular composition.
o Their use is restricted to the making of inner walls of furnaces for the manufacture
of metals and for similar high-temperature applications.

Classification:
o The firebricks are classified on the basis of their reactivity towards melts at high
temperatures:
o (a) Acidic Bricks. They are resistant to the melts of acidic composition (but will react
with the melts of basic composition).
o Example: Fire-clay bricks, silica bricks.
o (b) Basic Bricks. They are resistant to the melts of basic composition. Hence they
will not be suitable for use in those furnaces where acidic melts are being heated.
o Examples: Magnesia bricks, Bauxite bricks.
o (c) Neutral Bricks. They are non-reactive to both the acidic and basic melts. Hence
these find applications in heating either type of melts.
o Examples: Chromite bricks, Chrome-magnesite bricks.
o Manufacture of Fire Bricks.
o They are manufactured in the same manner as a building Brick. The four stages are
involved in their manufacture process are:
o Moulding
o Drying
o Burning
o Cooling
o The Raw Materials are first crushed in to the required size and then blended are
mixed thoroughly in the presence of required quantity of water.
o After this process Brick are molded manually or by using Machines such as
“Presser“.
o The molded Bricks are dried and then burnt in a very high temperatures, generally
between 1600 to 2000 Centigrade.
o After this Process they are allowed to cool very gradually.
o Description of important Fire Bricks or Refractory Bricks.
o (a. ) Fire Clay Bricks.
o These constitute are an important class of refractory materials of acidic group. Raw
material for its manufacturing can withstand at very high temperatures without
fusing or softening.
o Such clay are often available under the coal layers in nature.
o Silica ( 65-75 Percent) and alumina (25-35 Percent) are the two main constituents
of Fire Clay.
o They are free from impurities like oxides of calcium, magnesium andiron. The
maximum permissible upper limit for all such impurities is 5 Percent.
o These are manufactured in a manner similar to the common building Brick. The
selected clay is crushed to the fine powder and molded into the brick unit.
o These are than dried and burnt in Continuous kiln at very high temperature (1600 to
1900 centigrade).
o They are cooled gradually before taking out from the kiln.
o Types.
o They are divided into three types on the basis of temperature.
o High Duty. (1482 to 1648 Centigrade).
o Medium Duty ( 1315 to 1481 Centigrade)
o Low Duty (870 to 1314 Centigrade)
o Properties.
o They have high resistance to palling, high bearing capacity and low coefficient of
thermal expansion.
o Uses.
o They are commonly used as a lining material in steel making furnaces and
reverberatory furnaces.

o (b.) Silica Fire Bricks.

o These are made up mostly of silica, which may range from 95 percent or above. The
remaining material is generally calcium oxide that act as binding agent.
o These are acidic in character. Their raw materials is pure quartz (SiO2), or sandstone
of high silica content.
o The molded unit are burnt in about 1500 Centigrade. They are extensively used
in Bessemer Converter as lining material because slag in that case are acidic in
nature.
o (c.) Magnesite Fire Bricks.
o They are classed among the basic refractories. There raw material is magnesium
oxide. The major source for it is Dolomite rock.
o (d.) Bauxite Fire Brick.
o They also form a very important class of Basic Refractories. They are made from
the rock Bauxite ( Al2O32H2 ) which are mixed with some clay (Fire Clay type ).
o (e.) Chromite Fire Bricks.
o They are belong to the neutral class of refractories. Raw material used for these Fire
Bricks is a mineral called CHROMITE.
o The mineral is double oxide of chromium and iron in its composition. These types
Refractory bricks are capable of resisting both the acidic and basic environments in
a furnace.
o These type of fire brick are commonly used in the steel making furnaces

The process of manufacturing of bricks from clay involves preparation of clay,

molding and then drying and burning of bricks. The bricks are building
materials which are generally available as rectangular blocks. The bricks do not
require any dressing and brick laying is very simple compared to stone masonry.
Site selection for manufacturing of bricks
For the manufacturing of bricks, the site should be selected based on some important
considerations such as:

o The ground should be of plain surface.

o The site should be connected with communicating roads for transporting materials
etc.,
o Good brick earth should be easily available.
o The site should offer all facilities to the workers.
Manufacturing process of bricks
There are four different operations are involved in the process of manufacturing of
bricks:

1. Preparation of clay
2. Molding
3. Drying
4. Burning
1. Preparation of clay for brick manufacturing:
Preparation of clay for bricks manufacturing is done in six steps: Unsoiling of
clay We need pure clay for the preparation of bricks. The top layer of soil may
contains impurities, so the clay in top layer of soil about 200mm depth is thrown
away. This is called unsoiling. Digging After the removal of top layer, the clay is
dug out from the ground and spread on the plain ground. Cleaning In this stage, the
clay is cleaned of stones, vegetable matter etc. if large quantity of particulate matter
is present, then the clay is washed and screened. The lumps of clay are converted
into powder with earth crushing rollers.Weathering The cleaned clay is exposed to
 atmosphere for softening. The period of weathering may be 3 to 4 weeks or a full
rainy season. Generally, the clay is dug out just before the rainy season for larger
projects. Blending If we want to add any ingredient to the clay, it is to be added in
this stage by making the clay loose and spread the ingredient over it. Then take small
portion of clay into the hands and tuning it up and down in vertical direction. This
process is called blending of clay. Tempering In this stage, water is added to clay
and pressed or mixed. The pressing will be done by cattle or with feet of men for
small scale projects, pug mill is used as grinder for large scale projects. So, the clay
obtains the plastic nature and now it is suitable for molding.

2. Molding of clay for brick manufacturing

In the molding process, prepared clay is mold into brick shape (generally
rectangular). This process can be done in two ways according to scale of project.

o Hand molding ( for small scale)

o Machine molding ( for large scale)
Hand molding of bricks
If manufacturing of bricks is on a small scale and manpower is also cheap then we
can go for hand molding. The molds are in rectangular shape made of wood or steel
which are opened at the top and bottom. The longer sides of molds are projected out
of the box to serve it as handles. If we take durability in consideration steel molds
are better than wooden molds. In hand molding again there are two types and they
are

1. Ground molded bricks

2. Table-molded bricks
Ground molded bricks
o In this process of ground molding, first level the ground and sand or ash is sprinkled
over it.
o Now place the wet mold in the ground and filled it with tempered clay and press
hard to fill all corners of the mold. Extra clay is removed with metal strike or wood
strike or with wire.
o The mold is then lifted up and we have raw brick in the ground. And again wet the
mold by dipping it in water and repeat the same process. The process of dipping
mold every time to make bricks is called slop molding.
o Sometimes, the inside surface of mold is sprinkled with sand or ash instead of
dipping in water this is called sand molding
o Frog mark of bricks are made by using a pair of pallet boards. Frog mark means the
mark of depth which is placed on raw brick while molding. The depth may be 10mm
to 20mm.
o Frog mark stats the trademark of manufacturing company and also it is useful to
store mortar in it when the bricks is placed over it.
Table molded bricks
o This process is similar to ground molding process, but here the bricks on molded on
the table of size 2m x 1m.
o Ground molding is economical when compared to table molding.

Machine molding of bricks

The bricks required are in large quantity, then machine molding is economical and
also saves more time. Here also we are having two types of machines,
1. Plastic clay machines
2. Dry clay machines
Plastic clay machines This machines contain an opening in rectangular shape and
when we place the tempered clay in to this machine it will come out through this
opening. Now, the rectangular strips coming out the opening are cut by wires to get
required thickness of brick. So, these are also called wire cut bricks. Now these raw
bricks are ready for the drying process. Dry clay machines Dry clay machines are
more time saving machines. We can put the blended clay into these machines
directly without tempering. Means tempering is also done in this machine by adding
some water. When the required stiffness is obtained the clay is placed in mold and
pressed hard and well-shaped bricks are delivered. These are called pressed bricks
and these do not require drying they may directly sent to burning process.

3. Drying of raw bricks

o After molding process the bricks contain some amount of moisture in it. So, drying
is to be done otherwise they may cracked while burning. The drying of raw bricks is
done by natural process.
o The bricks are laid in stacks. A stack consists 8 to 10 stairs. The bricks in these stacks
should be arranged in such a way that circulation of air in between the bricks is free.
o The period of drying may be 3 to 10 days. It also depends upon the weather
conditions.
o The drying yards are also prepared on higher level than the normal ground for the
prevention of bricks from rain water.
o In Some situations artificial drying is adopted under special dryers or hot gases.
 4. Burning of bricks
o In the process of burning, the dried bricks are burned either in clamps (small scale)
or kilns (large scale) up to certain degree temperature. In this stage, the bricks will
gain hardness and strength so it is important stage in manufacturing of bricks.
o The temperature required for burning is about 1100oC. If they burnt beyond this
limit they will be brittle and easy to break. If they burnt under this limit, they will
not gain full strength and there is a chance to absorb moisture from the atmosphere.
o Hence burning should be done properly to meet the requirements of good brick.