Manufacturing Process of Bricks

Manufacturing Process of BricksA brick has been a common construction visible exampled e actuallywhere for more than 6000 years, and has been in various shape, sizes and were do by change integrity many contrasting type of materials, each of them having their own advantage and disadvantage and contriveed the grassroots structure and the back b ace of many civilisations and was partd in a wide range of creates in centuries from building palaces, housing factories, in tunnels construction, pissing supply ways, bridges, reservation it the nonagenarianest manufactured building material. For centuries, the brick making lick was d matchless(prenominal) by hand, and involved mud being moulded and then dried in the solariseshine until the industrial revolution when the act turned to mechanization. To day time technological and railcarlike advan cement has helped to hand over a more complete knowledge of the un exhibited material and its properties, and better control of vent, improvement in the kiln designs, all have contri excepted to the advancement of brick quality and has do contemporary bricks more efficient and has change the overall quality of the mathematical products.Today, brick is found in various materials and made in various shapes depending on the use. in that location argon concrete brick, calcium silicate brick, trunk brick and adobe brick brick. See Appendix 1This report get out be looking at the technology associated with the manufacturing branch of automated and traditional modify body brick, adobe brick plain mud brick which atomic number 18 still use today in certain part of the globe or sometimes and slump brick- and the future of brick.PART ONEMANUFACTURING answer OF AUTOMATED BRICKThe kickoff re-create in the manufacturing process of the soil mud brick start with the survival of the naked material.RAW MATERIALThe main raw material in brick making is mud and it is one of the most abundant natural mineral materials on the architectural planet. On earth, there is a wide range of corpse which varies con military positionrably in physical properties, colour, hardness and mineralogical content making it embarrassing to pinpoint particular system and say this is the best corpse for brick making but they do, however, have certain properties in common.PROPERTIES and TYPES OF claySClay is complex material as individual, and their deposits is unique referable to their specific modes of physical composition and physical characteristics, and be r bely present as thoroughgoing(a) minerals but rather atomic number 18 mixtures of the varied clay types of one group or type normally being dominant. But the Clay entering in brick manufacturing must(prenominal) deliver and fulfil some specific properties and characteristic such as the naught to be crushed and mixed with wet to form a shaping material which can be moulded into various shapes shrinkage or ostentatiousness pctage on firi ng, meaning when subject to appropriate temperatures the clay particles must fuse together the bloating characteristics, meaning the percentage of water absorption firing colour, meaning the colour of the brick after drying and percentage of fines produced upon curtailment and finish aptitude and these physical properties determine their commercial value.The clays from which burnt bricks are made whitethorn be divided into three principal types, all of which have comparable chemical compositions but polar physical characteristics.They are2. A come in Clays also called Alluvial and Drift ClaysFound near the surface of the earth, whitethorn be the up thrusts of older deposits or of more recent, sedimentary formation are readily worked and require little prepa circumscribe.2. B Shale clays or high-strung claysShale is sedimentary deposits clays that have been subjected to high advertiseures until they have hardened almost to the form of slate which are often difficult to work a nd necessitate the use of heavy mechanismry to extract but, may be brought into shaping condition by long weathering (i.e. by expo legitimate to rain, frost and sunshine) or by crushing and grinding in water, and they then resemble fair alluvial clays in every respect.2. C Fire ClaysFire clays are usually exploit at boneheadeder levels of the earth than other clays where they form the bed layer low seams of coal and have refractory qualities and a high degree of confrontation to heat.MANUFACTURING PROCESSThe process of making clay brick is generally uniform, although manufactures tailor their payoff to fit their particular raw materials.In general, the manufacturing process consists of essentially of six-spot stagesMining and Gathering raw materialsPreparation of raw material (crushing, grinding, covert and mixing the raw materials)Making of the brick or Forming Process (forming, cutting and coating)Drying hardening ( firing and changeing)Packaging and storingDiagram of t he industrial manufacturing process of clay bricks dig and GATHERING RAW MATERIALSThe prize of the mining method of clay exit depend on the kind of clay, on the depth, thickness, hardness and physical geology of the clay location under the ground.The general method of extracting clay from the quarry is in one case or twice a year using heavy gear up machinery to business pile large amounts, so to envision nonstop brick production regardless of the weather conditions and because clays are rarely present as pure minerals but rather mixtures of the different clay types research lab test of the clays from different parts of quarry go out determine the characteristics of the layers and result be stock in sepa localise different categories which leave behind facilitate the blending of the raw materials.PREPATION OF THE RAW MATERIALIn the manufacturer, the clay rock is crashed and invalidated in smaller particles, and then the material produced is screen through an inclined vi brating screening machine to control the particle sizes preliminary to water being added.During the screening, manufactures rig and compensate the different variations in chemical composition and physical properties by blending clays from different locations and sources to fit their standard of the end product. Consequently, to fulfil their requirements of perfect(a) clay for bricks making, or for the composition of the raw material to fulfil their standard, the different mixes and proportions of clay and chemical are blended together, precedent to add water, as which of them fall the working properties of clays causing them to vary in their behaviour touching the properties of the last-place product. At the same time, manufacture has standardized their end product and their manufacturing processes to limit variations in the processing and the inconsistency in end product.For instance, a clay brick that when be restored turn white may be essential commercially because, by a dding various minerals like oxide of iron allow chance upon the propriety of the brick in such a way that when cure it will produce a red brick if also there is consistency in the manufacturing processes.Example Clay containing from 5 to 8 % of oxide of iron will, under ordinary conditions of firing, produce a red brick but if the clay contains 3 to 4% of alkalis, or the brick is shoot too hard, the colour will be darker and purple. An redundant of Alumina compound tending to stag the colour lighter and brighter.FORMING OF THE BRICKThe origin step in forming process is to produce a homogeneous plastic clay visual modality work up into proper consistency by adding water to clay in a mixing put up with one or more revolving shafts with blade extensions. after the kneading, the plastic clay jalopy is ready for forming. there are three different methods of shaping and forming brick the stiff-mud process or extrusion process6. A. The stiff-mud process or extrusion processIn the stiff-mud process or extrusion process, the clay is mixed with expert enough water to produce clay plastic mass with water in the range of 10 to 15 percent of the clay mass. Next, the clay is extruded through a die, producing a horizontal column of clay which passes by conveyor belt through an automatic wire cutter to perform the individual brick. The cutter spaces and die size are precisely calculate to compensate for shrinkage during drying and firing.6. B. Soft-mud processIn the quiet-mud process or moulded process, the clay contains too much water to be extruded. The plastic clay mass contain 20 to 30 percent of water per mass is utilize to produce brick either by hand or machine. In the machine driven soft-mud process, standard brick are produce in mass quantities as the machine replicate the hand-making process much quicker.6. C. Hand makingIn the simplest form which is done by hand, the craftsman will produce one brick at the time by sufficeing a lump of soft clay in a mould and the excess clay is stuff from the top of the mould and the brick is turned out. The mould is lubricated with either backbone or water to prevent the brick from stick abouting in the mould.6. D. The dry-press processIn this process hydraulic or weightlifted air rams is utilise to press clay with very low plasticity, containing no more than ten percent of water by weight, into stigma moulds under pressures from 500 to 1500 psi creating a very compact and dense brick.DRYING PROCESSPrior to the brick to be fired in the kiln, after the brick is formed using any of the method describes above, it containing 7 to 30 percent of moisture, depending upon the forming method. This moisture must be removed introductory to the brick can be fired in the kiln otherwise, there will be formation of scum and certain mechanical defects from occurring or the brick will leap out when the brick is subject to the intense heat of the kiln. This drying process which last about 18 to 40 hour s, is normally done by placing the green brick in wrap dryer which utilize excess heat supplied from the exhaust heat of kiln to maximise thermal efficiency. To ensure good result, devices are installed to measure and control humidity in the drying facilities.A. FiringAfter the drying, the brick are fired in furnace chamber called kiln for 10 to 40 hours, where there are subject to a temperature of ranging betwixt 100 to 1200 degrees centigrade depending on clay type or material apply and the type of finished brick involve.During the process, clay particles and impurities will undergo changes as the temperature in the kilns rises. The remaining water in the brick will dry up or evaporate unlike the metal, clay softens slowly and melts or vitrifies gradually in rising temperature. The clay molecules mass breaks down becomes soft enough to stick together the mass becomes tight, so chapeau and non absorbent giving the brick it texture and colour. To ensure a good product and avoi d the brick to be deformed repayable to heat also called viscous fusion, kiln is fitted with sensors to control the temperature in the different stage the firing process.7.A.1. What is a Kiln?In brief, kilns are just containers for heat canled by natural gas, coal, sawdust, and methane gas from landfills or a combination of these fuels.There are many different types of kilns but the most common types are the continuous kilns (tunnel) which are always firing they never cool and are confident of turning out large quantities of bricks at steady constant rate and the periodic (intermittent) kilns which are fired on an intermittent schedule.http//www.pottery-magic.com/pottery/ history/bottle_kiln.htmPACKAGINGFollowing the firing process is the packaging but prior to that the bricks are gradually cool down, for 10 hours for tunnel kiln and form 5 to 24 hours in periodic kiln, as the rate of cooling affect directly the final colour of the bricks.After the brick has cool downs, there are unload from the kiln sorted, graded, packaged and place in a computer storage cubic yard or loaded rail cars or truck of delivery.PART deuceMANUFACTURING PROCESS OF ADOBE CLAY BRICKThe adobe brick, this type of earthen building materials has been around since the beginning of civilisation and has been the main building material for most of the civilisation. In our day, Adobe are mostly used in tempestuous and dry climates and become the characteristic of the third world.Although this is a very old material, it manufacturing process hasnt change since. As with the soil clay brick the main section which enter in the manufacturing process is clay and the manufacturing process start with the choice of the raw material.SELECTION OF RAW MATERIALSAdobe brick are made from a mixture of mud or clay and small pieces of straw or reeds, and are formed by hand and left in the sun to dry.The secret of make adobe bricks lays on the choice of the type of clay to use as it is made of surface cl ay soil. Although the bricks are made in rural bowl where there is no sophisticated laboratory for testing but prior using the clay it has to be tested.The testing of the clay can be done by filling 2/3 of a graded glass jar with the clay you plan to use, and then fill the jar with water and put a lid on. Shake the jar for about 2 minutes making sure the clay is totally mix up with the water then let the jar and the mix to sit overnight. After about 24 hours, run into the jar and its content the clay would have broken up into two distinct bands of sand on the bottom and clay on the top. There should not be more clay than sand on the ration of 30 percent clay and 70 percent sand for an saint adobe brick making clay.EQUIPMENT NEEDEDClay soilMeasuring immortaliseHammerHand Saw24 timbersNailsShovelBucket pissingStrawPREPARATION OF BRICKSAfter selecting the clay, an area must be consume prior to start making bricks and a shed to protect the pertly made against the rain as it can t ake a duette of days for them to dry.In the nearby, dig a hole of about 3 to 4 feet long, 2 to 3 feet wide and 2 to 3 feet deep as a mixing pit for the different ingredients. Then fill the hole with water and let it drain out as this will strengthen the wall of the hole for it not to crumble while mixing the clay soil. This will take at least a day to dry out.Make mould of the bricks using timber. The traditional size is 4 by 10 by 14 inches and this is made with 2 by 4 studs nailed into a ladder like shape.MAKING ADOBE BRICKS once the water in the pit has dry out, fill the pit middle(a) with the clay soil then add water gradually as mixing with the feet our power shovel until the mix is stiff. Straw can be added to reinforce the mix but it is not infallible.Fill the mould using a shovel or hand thenlevel off the excess with the shovel or with a straight edge, makingsure there are no air pockets or gaps. allow the bricks set and then gently remove the mould from them leaving the crocked adobe bricks to dry for several days (at least three) before handling. clean the mould and repeat the process in a different area.DRYING PROCESSLeave the adobe brick where they are while they dry in the sun for several days before turning them on the edge to totally dry out and harden and put under the shed so that the drying time can continue. When the edges turn white, they are ready to be moved, but not used. This process could take at least 3 weeks prior the brick is use.PART THREETHE FUTURE OF CLAY BRICKAs the world commonwealth is growing especially in evolution countries, there is a take aim of urbanisation to accommodate this populace meaning more bricks are necessitate to answer to this demand of infrastructure development. With the growing problem of energy monetary value soaring, with the world running out of fossil fuel, with the reduction of deforestation which encourages the working out of the desert, the clay brick industry is now facing an energy cri sis and this crisis is affecting and will affect everyone. In the developed country, it is affecting the equipment casualty of the accommodation and the theatre price while in the evolution country it is leading to the meagreness of many. This crisis resound as called for innovation by bread and butter a raw(a) way of making raw(a) type of clay brick or amend the firing process by a new design of kiln aiming to reduce energy consumption by minimizing the energy required by the process as firing time and temperature in the kiln are the two get word factors which contribute in the making of solid brick.In the developed country, electricity and fossil fuel are use as the main fuel source for brick firing as they are abundant. Founding other substitute to these sources of energy could be the way forward. But investing in nuclear power will raise an environmental issue of dealing with the nuclear waste investing in the renewable energy will be a gamble in the way that, most of this technology are still in embryonic state and will require funding a good spot to install them and a big area to cover to be able to produce enough energy necessary to power this industries such investment will impair on the price of brick. It will mean also to divert energy which will be helpful to thousand household into industry.UNFIRED CLAY BRICKThe way forward will be probably in reducing the energy consumption by designing better kiln and improving our knowledge of the minimum energy required by the process as unnecessary prolonged firing time and too high temperature will eventually consume more energy but minimum firing temperature and shortening firing time do not only reduce energy but also addition the productivity.In the developing country, this crisis reverberates as called for innovation, finding an alternative for solidification clay brick as they are facing desertification. Curing is done, depending on the area, by fire wood, rice husk and maize cob or residue as main fuel sources for brick firing because they are abundant in developing country. Even though other agricultural waste such as saw dust and oil palm shell are used as substitute for wood, a new design of kiln is necessary to dole out with the small size of fuel.If thinking in term of innovation in finding a new way of making clay brick, the new brick should be energy efficient in manufacturing process especial if cure through a kiln. Although the adobe clay brick may seem to be the answer but this brick however is not very strong or durable and tend to crack on drying.But one of the ultramodern additions is to compensate this weakness by mixing soil clay with sand and stabilizing it with 4 to 8 % of cement or gypsum and then compress these materials in a given mould form, which results in strong and durable bricks, which do not crack. This is done with simple and yet innovative manually or engine-operated brick presses made from substantial steel sections with axle steel sha ft with a top round shaft is case hardened carbon steel with a lid and with a bottom that moves up and down the abridgement given by the machine compact the soil particles together to make dense regular shaped brick, usually 300x300x 130 mm in size and it is useto produce interlocking soil clay bricks without burning.MANUFACTURING UNFIRED CLAY BRICKSThis process uses the same type of clay use for the adobe brick. After the soil clay has been selected, it must be properly mix with Portland cement or gypsum then add water to the content so that the final product is a dry mixture containing about 15% water by weight. The dry mixture is poured in the mould of the press machine which is compress by pushing the press lever from one side to the other after closure of the top with a steel lid, with a force of about12 to 14 tons mould pressure. After the compression finish, the brick is unfreeze from the machine and stack in the way to prevent water loss. water system is added daily so tha t the cement can be hydrated properly. The curing process will take about 28 days.ADVANTAGESThis Environmentally-sound building process is practical, inexpensive andenvironmentallyHYPERLINK http//www.articlesfactory.com/articles/environment/soil-brick-making-machines-can-save-the-forests.htmlHYPERLINK http//www.articlesfactory.com/articles/environment/soil-brick-making-machines-can-save-the-forests.htmlfriendly, as well as world-shaking in cost savings and on-going green benefits, building with unfired soil clay bricks is one of the solution for the housing crisis because it has a lot of environmental benefits. grade 2The environment is protected in several waysIt lessens the ecological impact of building construction, thereby reducing deforestation and the need kiln. There is hence no need to burn the bricks, which makes this process a very low-energy requiring one.It saves money as the brick can be made On-site eliminating transportation, middlemen and break cost.On the other hand, unfired clay brick provide a sustainable and well-preserved alternative as replacement to established masonry materials.The structures made with soil bricks are as beautiful and durable as housing made from conventional bricks with the higher acoustical qualities that shut out exterior noise for less stressful living and reduce the need to heat or cool the interior. The soil brick is suitable especially for use in multi storey buildings, due to its durability and robustness.The bricks are already strong enough to be handled for storage when they leave the machine.Brick presses allow countryside people to build independently their own low-cost bricks to self-build their houses and not have to rely on salesmen and production in towns, icky roads, transport problems and fluctuating prices.CONCLUSIONThe lack of fossil fuels the world will face shortly will drive the world in an stinting crisis which we havent experience before driving up the price of accommodation. Though the t opic of compress clay bricks from soil is far from new in the developing country, but for some unknownreasons this technology doesnt seem to have made its brake through the developed world. There is a need to pass this new product of a low carbon footprint in the building industry.REFERENCEShttp//sleekfreak.ath.cx81/3wdev/VITAHTML/SUBLEV/EN1/CLAYPROD.HTM/how_242553_.htmlwww.ibstock.com/pdfs/technical/TIS16howbrickaremadehttp//www.articlesfactory.com/articles/environment/soil-brick-making-machines-can-save-the-forests.htmlhttp//www.newdawnengineering.com/website/brickandtile/tbrick/http//opus.bath.ac.uk/16170/1/papers/ base%2031.pdfwww.bia.org/bia/technotes/t9.htmlREPORTManufacturing of Bricks 9.12.2006Publish The Brick Industry Associationwww.gobrick.com/omnisam/common/getfile.cfm?file=/bia/technotes/t9 gate 20.03.2010Careful humidity controlPublish Vaisala news 1998Www. Vaisala.comAccess 24.03.10 first rudiment of making Adobe bricksPublish College of agriculture and home economic s rising Mexico state university March 2003www.aces.nmsu.eduAccess 24.03.10WebsitesMineral information institutewww.mii.org16.03.10 lustrous Hubwww.brighthub.com13.03.10University College Londonwww.es.ucl.ac.uk13.03.10Answer.com/reference answerwww.answer.com17.03.2010How to make adobe brickswww.ehow.com17.03.2010How to make Adobe brickswww.doityourself.com07.04.2010