Burnt Clay Bricks Manufacturing Process- Civilengicon

Civil Engicon Team
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Update: January 22, 2023

Bricks-Manufacturing Process

Welcome to Civil Engicon. We are here to know about step-by-step procedure to manufacture burnt clay bricks. Since clay bricks are used over world, some process and information may vary along with region of manufacturing and availability of materials. After reading this blog we can answer brick manufacturing process related answers.

Step-By-Step Procedure For Brick Manufacturing Process:

Burnt Clay Bricks are one of the most popular building materials in the world. They have been used for centuries, and they are known for their durability, fire-resistance, and long-lasting nature. In this blog post, we will take a detailed look at the manufacturing process of burnt clay bricks, from extracting the clay to firing the bricks.

1. Extracting Clay: The first step in the manufacturing process is to extract clay from the ground. This is typically done by excavating clay pits, which are then transported to the manufacturing facility. The clay is then screened and cleaned to remove any impurities or debris. This is a crucial step, as impurities can affect the quality of the final product.

Composition of Clay Brick:

  1. Silica (Sand):  50 to 60 % by weight.
  2. Alumina (Clay): 20 to 30 % by weight.
  3. Lime: 2 to 5% by weight.
2. Preparing The Clay: Once the clay has been extracted and cleaned, it is then mixed with water to form a homogeneous mixture. This mixture is then placed in a pug mill, which is a machine that kneads and mixes the clay to the desired consistency. This step is important, as it ensures that the clay is of the right consistency for shaping and firing. Sometimes it is table-moulded and wire-cut for shaping the bricks.

3. Shaping/Moulding The Bricks: The next step is to shape the bricks. This is typically done by using a brick press, which forms the clay into the desired shape and size. The bricks are then placed on pallets and left to dry for several days. This step is important, as the bricks need to be dry before they can be fired. 

Size of Bricks:

a.) Modular Bricks; b.) Non- Modular Bricks.

The standard Modular Size of common building bricks should be:-

Length (L)Width (W)Height (H)

The Non-Modular Sizes of the bricks may be used in building:-

Length (L)Width (W)Height (H)

Standard Size of Bricks:

The Standard Size of Bricks is 190x90x90 mm (length x width x height) or,
The Standard Size of Bricks is 19x9x9 cm (length x width x height) or,
The Standard Size of Brick in Inches is 7.48x3.45x3.45 (length x width x height).

4. Firing The Bricks:
Once the bricks have dried, they are then fired in a kiln. This is a large, industrial-grade oven that is heated to extremely high temperatures, typically around 1000-1200 degrees Celsius. The bricks are left in the kiln for several hours, during which time they undergo a chemical reaction known as sintering. This process hardens the bricks and gives them their characteristic red color. This step is crucial, as it is what gives the bricks their strength and durability.

5. Quality Control: After the firing process, the bricks are inspected for quality control. They are checked for size, shape, color, strength, and other parameters. The bricks that pass the quality control test are packaged and sent for delivery, while the bricks that fail the test are discarded. This step is crucial, as it ensures that only high-quality bricks are used in construction.

Types of Burnt Clay Bricks:

  1. First Class Bricks
  2. Second Class Bricks
  3. Third Class Bricks
  4. Fourth Class Bricks
6. Aging: After the bricks are removed from the kiln, they are left to cool and age for several weeks. This allows the bricks to fully harden and reach their maximum strength.

7. Grading: After aging, the bricks are graded according to their strength and size. Bricks that meet the required standards are labeled as first-grade bricks, while those that do not meet the standards are labeled as seconds.

8. Stacking: The bricks are stacked in a specific manner to ensure proper air circulation and prevent cracking. This is known as “curing”.

9. Packaging: After grading and stacking, the bricks are then packaged and prepared for delivery to the construction site.

10. Recycling Waste Materials: Many modern brick manufacturing plants recycle waste materials, such as fly ash and slag, to reduce their environmental impact. This also helps to reduce the cost of production.

11. Automation: Many brick manufacturing plants have started to use automated systems for some or all of the manufacturing processes, such as moulding and firing. This helps to increase production efficiency and reduce labor costs.

12. Energy Conservation: Many brick manufacturing plants have implemented energy-saving measures, such as using renewable energy sources, to reduce their environmental impact and lower production costs.

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