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Bricks Manufacture - Edu-Civil.pptx

The document outlines the brick manufacturing process, detailing the preparation of clay, moulding, drying, and burning stages. It describes various methods and types of moulding, drying techniques, and the importance of proper burning temperatures and methods to ensure brick quality. Additionally, it explains different types of kilns used for burning bricks, including intermittent and continuous kilns, highlighting their operational differences.
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0% found this document useful (0 votes)
22 views36 pages

Bricks Manufacture - Edu-Civil.pptx

The document outlines the brick manufacturing process, detailing the preparation of clay, moulding, drying, and burning stages. It describes various methods and types of moulding, drying techniques, and the importance of proper burning temperatures and methods to ensure brick quality. Additionally, it explains different types of kilns used for burning bricks, including intermittent and continuous kilns, highlighting their operational differences.
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Bricks II

AMMU S
Bricks
Manufacture of Brick
● Preparation of Clay
● A. Unsoiling: top 200 mm of soil is thrown and is not as it consists
of majority of impurities in it
● B. Digging: soil is dug out and spread over the level filed to
prepare it for next operation of cleaning -60-120 cm depth.
● C. Cleaning: Impurities like stones, pebbles, organic matter,
vegetation matter is removed from the brick earth.
● D. Weathering: after cleaning the clay it is imposed to the
atmosphere for few weeks to few months for its softening,
ripening and weathering
Manufacture of Brick
● 1. Preparation of Clay
● E. Blending: It is process in which different ingredients of bricks
earth is spread over the weathered clay in definite proportion and
mixed.
● F. Tempering: Tempering is the process in which requested degree
of hardness is induced in the brick earth to make it suitable for
the next operation of moulding.
● - Tempering of the brick is done in "pug mill"
Manufacture of Brick
● Moulding of Clay
● The process of giving desired shape and size to the bricks is
termed as moulding.
● Steel or wood moulds are used, size of which is approximately
kept to be 8-12% greater than the size of the bricks in order to
account for its shrinkage.


Manufacture of Brick
● Moulding of Clay
● During moulding a mark of depth 10-20 mm is placed over the
surface of the brick that is termed as frog mark, which serves
following two purpose:
● i) Trade name of the manufacturer.
● ii) If acts a key for mortar when the layer of bricks is placed over
it.


Manufacture of Brick
2. Moulding of Clay
● Moulding of the bricks can be done with the help of hand or with
the help of machines.
● Hand moulded bricks are further of two types:
● a) Ground moulded bricks
● b) Table moulded bricks
● Qualities of table moulded bricks in comparatively better than the
quality of ground moulded bricks and its rate of moulding is also
comparatively better than ground moulded bricks.
Manufacture of Brick
2. Moulding of Clay
● Machine moulded bricks are also of two types:

● a) Plastic clay moulded bricks


● b) Dry clay moulded bricks
● Quality of dry clay moulded bricks is also comparatively better
than plastic clay moulded bricks.
Manufacture of Brick
Manufacture of Brick
● 3. Drying –
● Moulded bricks, if are directly burnt without drying are to liable to
get crack due to excessive shrinkage, hence its drying is carried
out before the burning of pressure in which moisture content of
the brick is reduced up to 2%
● Drying of the bricks is carried out either naturally or artificially
● During drying, bricks are always placed along their edge and never
placed along there face, in order to speed up the process of
drying.
Manufacture of Brick
● 3. Drying –


Manufacture of Brick
● 4. Burning of Bricks
● Burning impacts strength and hardness to the bricks, it makes
them dense and durable
● Burning should be done properly
● Overburnt- Brittle/easily broken
● Underburnt- Soft/unable to carry designed load
● Burning of the bricks is carried out at 1100°C at which silica and
lime fuse with each other thereby imparting strength to the
bricks
Manufacture of Brick

Manufacture of Brick
● Burning of Bricks Burning occurs in 3 stages:
● a) Dehydration/Water smoking stage (400 - 650°C)
● • Water from pores is driven off
● • Some of carbonaceous matter is burnt
● b) Oxidation Period(650-900°C) Remaining carbon is burnt
● Ferrous Iron is converted into Ferric Iron
● Sand is added to allow escaping of gases
● c) Vitrification(900-1100°C)
● To convert the mass into glass like substance
Manufacture of Brick
● 4. Burning of Bricks
● Burning impacts strength and hardness to the bricks, it makes
them dense and durable
● Burning should be done properly
● Overburnt- Brittle/easily broken
● Underburnt- Soft/unable to carry designed load
● Burning of the bricks is carried out at 1100°C at which silica and
lime fuse with each other thereby imparting strength to the
bricks
Manufacture of Brick
● 4. Burning of Bricks
● a) Burning of Bricks in Clamps
● Trapezoidal section of ground is taken and longer side is raised
with 15 degrees
● A brick wall in mud is constructed along the shorter side and the
fuel layer having thickness of 700 to 800 mm spread over the
level ground.
● Fuel used for burning of the bricks in clamps constitutes grass,
rice husk ash, wood, cow dung, coal dust etc
Manufacture of Brick
● 4. Burning of Bricks
● a) Burning of Bricks in Clamps
Manufacture of Brick
● a) Burning of Bricks in Clamps
● Burning of the brick in clamp is carried out for 2-3 months that is
further following by its cooling for same duration.
● No supervision is required in clamps, moreover since locally
available fuel is used, the entire process is comparatively
economical.
● There is no control over the fire in clamps, hence the bricks
obtained are not of uniform quality.

Manufacture of Brick
● a) Burning of Bricks in Clamps

Manufacture of Brick
● 4. Burning of Bricks
● b) Burning of Bricks in Kilns
● Kilns are large sized oven that are used for the burning of bricks.
● Supply of the bricks from these kilns may either be continuous or
intermittent accordingly. They are classified as-
Manufacture of Brick
● 4. Burning of Bricks
● b) Burning of Bricks in Kilns
● i) Intermittent Kilns
● All the operations of loading, burning, cooling and unloading is
done sequentially and, hence the supply of the bricks is not
continuous from these kilns
● Consists of two sets of main doors that are used for loading and
unloading the bricks.
Manufacture of Brick
● 4. Burning of Bricks
● b) Burning of Bricks in Kilns
● i) Intermittent Kilns
● Bricks are placed in these kilns in the rows of approximately 4-5
brick thick and height of approximately 6-8 brick thick
● An open space between the two rows of approx 2-3 bricks thick is
left which is used for placing the fuel.
Manufacture of Brick
● b) Burning of Bricks in Kilns
● i) Intermittent Kilns
● 1. Up Draught kilns: If the movement of the gases is allowed to
take place in vertically upward direction, it is termed as Up
Draught kilns
● 2. Down draught kilns: If the movement of gases is allowed to
take place in vertically downward direction, it is termed as Down
draught kilns
Manufacture of Brick
● b) Burning of Bricks in Kilns
● i) Intermittent Kilns
● In down draught kilns permanent roof is provided along with the
central chimney that permits the movement of the gases in
downward direction.
● ✓ Qualities of the brick obtained from Down draught kilns is
comparatively better than that of bricks obtained from up
draught kilns.
Manufacture of Brick
● 4. Burning of Bricks
● b) Burning of Bricks in Kilns
● ii) Continuous Kilns
● In continuous kilns, the supply of the bricks is maintained to be
continuous as all the operations of loading, burning, cooling and
unloading is done simultaneously
Manufacture of Brick
● A. Bull Trench Kiln
● It includes two sets of movable chimneys that are always placed
ahead of the section in which burning is to be carried out. Such an
arrangement allows the pre heating of the bricks in the chamber
over which chimney is placed.
● This kiln consists of number of sections in which all the
operations of loading, burning, cooling and unloading is done
simultaneously.
● These kilns are generally oval, circular & rectangular in plan
Manufacture of Brick
● A. Bull Trench Kiln
Manufacture of Brick
● ii) Continuous Kilns
● B. Hoffmann Kiln
● This kiln is circular in plan and consists of fixed central chimney
unlikely Bull trench kiln that consists of moveable chimneys
● This kiln consists of number of sections in which all the
operations of loading, burning, cooling and unloading is done
Manufacture of Brick
Manufacture of Brick
● ii) Continuous Kilns
● C. Tunnel Kiln
● This kiln is in the form of tunnel which may either be rectangular,
circular or oval in plan.
● It consists of different stationary zones in which all the process of
loading, burning, cooling and unloading is done simultaneously.
● Bricks are placed either on trolley or on conveyer belts and is
passed through different stationary zones in the tunnel
Manufacture of Brick
● ii) Continuous Kilns
● C. Tunnel Kiln
● This kiln is in the form of tunnel which may either be rectangular,
circular or oval in plan.
● It consists of different stationary zones in which all the process of
loading, burning, cooling and unloading is done simultaneously.
● Bricks are placed either on trolley or on conveyer belts and is
passed through different stationary zones in the tunnel
Manufacture of Brick
Manufacture of Brick
● ii) Continuous Kilns
● C. Tunnel Kiln
● This kiln is in the form of tunnel which may either be rectangular,
circular or oval in plan.
● It consists of different stationary zones in which all the process of
loading, burning, cooling and unloading is done simultaneously.
● Bricks are placed either on trolley or on conveyer belts and is
passed through different stationary zones in the tunnel
Manufacture of Brick
● ii) Continuous Kilns
● C. Tunnel Kiln
● This kiln is in the form of tunnel which may either be rectangular,
circular or oval in plan.
● It consists of different stationary zones in which all the process of
loading, burning, cooling and unloading is done simultaneously.
● Bricks are placed either on trolley or on conveyer belts and is
passed through different stationary zones in the tunnel
THANK YOU

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