Manufacture of bricks by vishwajeet kumar
- 2. Preparation of brick earth Moulding of bricks Drying of bricks Burning of bricks
- 3. Removal of loose soil The 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 cleaning The earth is then dug out from the ground. This earth is spread into heaps about 50 to 150 cm height. Blending and tempering The 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
- 5. Hand moulding When 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 moulding The 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. These bricks are also called wire cut bricks.
- 8. 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.
- 9. A typical scove kiln. A typical clamp kiln. A typical scotch kiln.
- 10. CONTINOUS KILN BURNING – HOFFMAN, BULL’S TRENCH, 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.
- 11. HOFFMANN KILN – ORIGINAL
- 12. • Widely used in China = 90% of bricks • Can use coal or natural gas
- 13. BULL’S TRENCH KILN Used in India, Pakistan,Nepal, Bangladesh Uses coal. “Movable chimney” (MC) and “Fixed” Fixed (FC) MCBTK banned (but still used) in India, parts of Nepal & Pakistan due to very high emissions KILN with Movable chimney
- 15. HABLA ZIGZAG KILN Effective tunnel length of Hoffmann increased with “zigzags” made of green bricks Larger capacity and more efficient than other kilns Needs fan to draw air through = needs source of electricity
- 16. Loaded at top, bricks removed from bottom • High efficiency, low emissions • Kiln are in India, Nepal, Pakistan, Vietnam VERTICAL SHAFT BRICK KILN (VSBK)
- 17. Unburnt or sun dried bricks These are dried under sunlight. These are used for temporary and cheap construction. It is also used for filling works. Burnt bricks • First class bricks • Second class bricks • Third class bricks • Fourth class bricks CLASSIFICATION OF BRICKS
- 18. FIRST CLASS BRICKS Made of good earth which is free from saline deposits and are sand molded. Burnt completely and have deep red, cherry and copper color. Regular and uniform in shape and size with sharp and square edges and parallel faces. It emit a clear ringing sound on being struck together. Free from cracks, stones and lime. Have a minimum crushing strength of 105 kg per sq. cm when tested according to the test
- 19. SECOND CLASS BRICKS They shall be well burnt or slightly over burnt. They must give clear ringing sound when struck. The may have slight irregularities in size, shape and color. They may have slight chips, flaws or surface crack but must be free from lime or kankar. The minimum crushing strength of second class brick should be 70 kg per sq cm.
- 20. THIRD CLASS BRICKS These bricks are slightly under burnt or over burnt. They are not uniform in shape, size and edges. They shall not observe water more than 25% of their own dry weight after 24 hours, immersion in cold water. They have some signs of efflorescence
- 21. FOURTH CLASS BRICKS These are over burnt bricks which are dark in colour and are irregular in size and shape. These are used as aggregate in concrete and for flooring. Over burnt bricks are not used for building construction.
- 22. Thank you !