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CE 203
ENGINEERING MATERIALS
BRICKS
Shovon Halder
Assistant Professor
Department of Civil Engineering
Chittagong University of Engineering & Technology
Bricks
• Bricks are blocks of tampered clay, cement, sand, or other
materials molded to suitable shapes and sizes while still in plastic
condition. They are then dried in the sun and burnt to make them
stronger, harder, and more durable.
• Bricks are normally rectangular in shape, and their size is set to
make them easy for workers to handle.
• Bricks are very popular and widely used construction materials
because, they are cheap, durable and they are easy to handle and
work with
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Size of Bricks
• Size and shape of bricks can be made over a wide range
depending on purpose of use.
• The standard size of bricks in our country according to P.W.D., is -
9.5"x4.5"x2.75". There are other sized bricks also. But this size is
most economical because when bricks are put in any construction
with mortar the size becomes 10"×5"× 3" (approximately).
Therefore, the sizes of walls which are constructed by bricks in our
country are 3", 5", 10", 15", 20", 25" and 30". The standard size of
bricks can be used safely without any breakage
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Frog mark
A frog mark is a depression of about 1 to 2-inch depth made on the face of
the bricks while molding the bricks.
Frog marks serve two functions:
• A frog mark facilitates the bonding of bricks with the course of bricks
above them.
• The trademark or identification mark of the manufacturer is also indicated
on the frog
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Classification of Bricks
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Classifications based on physical and mechanical
properties
Bricks can be classified as:
i. S-grade (or 1st Class brick)
ii. A-grade (or 2nd Class brick)
iii. B-grade (or 3rd class brick)
iv. Over-burnt or Jhama brick
v. Under-burnt brick
Note that this classification is applicable mostly for burnt clay bricks
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Classifications based on physical and mechanical
properties
S-grade (or 1st Class brick):
Standard Size; Uniform yellow or red colored;
Well brunt; Regular shape; Uniform texture
No efflorescence; No pebbles, gravels or organic matter;
Water absorption capacity ≤ 12-15% when immersed in cold water for 24
hours.;
Crushing strength: σmean= 4000 psi & σmin= 3500 psi;
Emits a metallic sound; No fingernail impression.
Usage:
in building of long durability, say 100 years.
for buildings exposed to corrosive environments;
for making coarse aggregate of concrete.
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Classifications based on physical and mechanical
properties
A-grade (or 2nd Class brick):
• Standard Size; Uniform yellow or red colored;
• Well brunt (slightly over-brunt is acceptable);
• Regular shape; Efflorescence is not appreciable;
• 15% < Water absorption capacity ≤ 20%;
• Crushing strength: σmean = 2500 psi; σmin = 2200 psi;
• Emits a metallic sound; No fingernail impression.
Usage:
• used in partition walls.
• preferred as brick ballast in foundations & floorings
• for all important or unimportant hidden masonry works
• for the construction of one-storied building, temporary shed
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Classifications based on physical and mechanical
properties
B-grade (or 3rd Class brick):
• Soft and light red colored; Shape and size not regular;
• Under brunt (slightly over-brunt is acceptable);
• Extensive efflorescence; Non-uniform texture;
• 20% <AC ≤ 25%;
• Crushing strength: σmean = 2000 psi; σmin = 1500 psi
• It emits dull/blunt sound;
• Left fingernail impression
Usage:
• Though they have poor strength and texture, they are highly economical and
can be used in the construction of temporary and rural structures
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Classifications based on physical and mechanical
properties
Over-brunt or Jhama brick:
• Non-uniform color –red, black mixed;
• Shape distorted (as larger than the required amount of silica gets fused);
• High water absorption capacity;
• Strength may be higher or equivalent to S-grade (or 1st class) brick.
• Usage:
• have very low strength and are not recommended for application in
major construction works.
• used in flooring, and inferior construction works.
• lime concrete for foundation
• In making shurki/coarse aggregates.
• In concrete of slab and beam which will not come in contact of water.
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Classifications based on physical and mechanical
properties
Under-brunt brick:
§ Half brunt brick;
§ Yellow colored;
§ Low strength;
§ Such bricks should not be exposed to rainwater
Usage:
üsurki in lime-terracing;
üsoling under RCC footing or basement
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Classifications based on Raw materials used
Depending on raw materials used in manufacturing bricks can be classified
as:
• Burnt clay bricks
• Fire clay/ refractory /engineering bricks
• Fly ash clay bricks
• Sand lime bricks
• Concrete bricks
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Classifications based on Raw materials used
Rich in
“Kaolinite”
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Classifications based on Raw materials used
Burnt Clay Bricks:
• It is obtained by pressing the clay in molds and fried and
dried in kilns. Burnt clay bricks are commonly used in
construction across the globe. It requires plastering when
used in construction
• Burnt clay bricks are extensively used in our country, so this
lecture contains details of their properties and manufacturing
processes.
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Classifications based on Raw materials used
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Classifications based on Raw materials used
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Classifications based on Raw materials used
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Classifications based on Raw materials used
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Classifications based on shape
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Classifications based on ASTM
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Chemical Composition
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Chemical Composition
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Chemical Composition
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Chemical Composition
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Chemical Composition
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Harmful Ingredients of Brick
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Harmful Ingredients of Brick
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Harmful Ingredients of Brick
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Brick Characteristics
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Manufacturing of Burnt Clay Bricks in Kilns
The process of manufacturing bricks from clay involves five basic
stages. Each stage can be processed differently, depending on the
type of kiln, the technology used, etc.
1. Preparation of raw ingredients;
2. Pugging or tempering of clay;
3. Molding of bricks;
4. Drying of bricks;
5. Burning of bricks
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1. Preparation of raw ingredients (clay/silica/alumina…):
It involves operations like un-soiling the top loose earth, then digging,
cleaning, weathering, and blending the earth. After removing the top
unsuitable soil, the clay is dug out, spread on the leveled ground, and left
exposed to the atmosphere for softening. Digging the earth before rains is
advantageous; the full monsoon can be utilized for weathering the earth.
After weathering, the earth is chemically analyzed. If any ingredient
deficiency is observed, it should be added correspondingly.
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Pugging or tempering of raw materials:
This step involves breaking up of prepared clay, watering,
and kneading till the earth becomes a homogeneous mass.
Then water is added in the required quantity. The whole
mass is kneaded manually (under the feet of men or cattle)
or mechanically with using Pug-mill.
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Molding of bricks:
After the tempering of clay, bricks should be molded as soon as
possible. Otherwise, the pugged clay may become stiff and molding
brick may become difficult. Molds are made slightly larger than the
standard size of the brick to compensate for shrinkage when drying and
burning.
Molding is of two types: hand molding (ground molding and table
molding) & machine molding. Molding directly on the ground has two
drawbacks:
i) the lower face is very rough; ii) Bricks cannot have frog marks.
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Drying of bricks:
The objectives of drying the bricks are
i) to remove as much moisture from bricks as possible to
save fuel and time while burning.
ii) to avoid the chances of cracking and distortion of bricks
during burning and
iii) to increase the mechanical strength of bricks so that they
can be handled and stocked without any damage to the raw
bricks.
Drying can be done either using sunlight or by hot airflow in
the kiln.
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Drying of bricks:
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Kiln:
A kiln is a thermally insulated chamber, a type of oven, which produces
temperatures sufficient to complete some process of hardening, drying, or
chemical changes and finally making burnt brick.
Depending on the manufacturing process two types of kilns are used in
brick production:
i) Intermittent kiln;
ii Continuous kiln; e.g. Hoffman’s kiln, Tunnel kiln, Rotary / Mobile /
automatic kiln, etc.
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Advantages-
- Suitable for small quantities of brick production at a time.
- Less costly than continuous kiln
Disadvantages -
- The supply of bricks is intermittent
- Quality of burning is non-uniform: near the bottom, the
bricks are over-burnt and near the top are under-burnt.
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Continuous Kiln
Such kiln consists of a series of connected kilns or one continuous
chamber, through which a fire travels, green brick being set ahead of the
fire, gradually passes through process of drying, preheating, burning,
cooling and then brining out ready brick from kiln.
Most commonly used continuous kilns are–
i. Hoffman’s kiln
ii. Tunnel kiln
iii. Rotary/ automatic kiln
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Hoffman’s Kiln
This kiln is circular in plan; Modern Hoffman’s Kilns are of oval shape. For air
outflow, chimney is placed at the central point
Advantages of Hoffman Kiln:
• Better control on heat;
• Supply of bricks is continuous;
• Bricks are burnt evenly; bricks of good quality are produced;
Disadvantages of Hoffman Kiln:
• Initial cost is high;
• Requires regular demand of the bricks, which may not be possible.
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Hoffman’s Kiln
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Hoffman’s Kiln
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Tunnel kiln
In a tunnel kiln dry bricks are loaded onto a fireproof trolley or kiln car. This then
travels very slowly through the kiln. Typical schedule through the kiln from end to
end is 3-7 days but variations occur depending on production schedules. Although
tunnel kilns are generally more expensive to build than chamber kilns they are
more economical to run and lend themselves to high degrees of automatic control.
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Rotary / Mobile tunnel kiln
Rotary tunnel kiln is improved and upgraded from traditional tunnel kiln. Its biggest
characteristic is the adobes stay still while the body of rotary kiln moves. Rotation movement
of the kiln body in orbit intermittent forward - front eat bricks back end spit finished bricks, in
turn, drying, preheating, firing, cooling, the whole process of bricks.
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Pollution from Traditional Brick Industry
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Green Technology- AAC Block
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Green Technology- AAC Block in BD
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Laboratory Test of Bricks
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Compressive/ Crushing Strength Test
The most important test for brick is to determine its
compression capacity. In the ASTM standard for clay bricks,
a compressive strength test is done on five half bricks
(halved lengthwise). The average of the obtained values is
used to determine the compressive strength of the whole lot
of brick.
Different standards are followed for different types of brick:
§ for clay bricks – ASTM C67
§ for concrete blocks – ASTM C140
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Laboratory
Laboratory Test of BricksTest of Bricks
Sample Compressive Average Water Avg. Water
No. Strength Compressive Absorption Absorption (%)
MPa (psi) Strength (%)
MPa (psi)
Frog Mark: R&C
1 14.4 (2090) 17.5
2 9.6 (1390) 14.2
3 18.4 (2670) 12.2 (1770) 12.9 15.2
4 9.3 (1350) 19
5 9.5 (1380) 12.5
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Test of Water Absorption Capacity
This test determines the porosity of bricks, which can then be
used to indicate the potential for problems related to the
penetration of salts and other materials into the units, such as salt
attack and efflorescence.
Absorption test is carried out on five half bricks. Bricks are oven-
dried, weighed, and kept immersed in water for 24 hours. SSD
weight of bricks is measured.
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Efflorescence
Efflorescence is a crystalline deposit of salts often found on the surface of
concrete, brick, stucco, or natural stone. Although unattractive, efflorescence is
usually harmless. In rare cases, excessive efflorescence within the material's
pores can cause expansion that may disrupt the surface.
For this test, five pairs of bricks are taken for an efflorescence test. One brick from
each pair is immersed in distilled water at a one-inch depth for seven days, while
the other five bricks are kept in air.
After 7 days, all bricks are oven-dried and examined for efflorescence. Each pair
of bricks is compared. If the brick immersed in water has a different texture than
its pair, it is considered effloresced.
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Density/Unit Weight
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Distortion / Warpage
The amount of distortion is based on the brick
specification and face dimension. Distortion may be
convex or concave and may be in the plane of the wall or
perpendicular to it.
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Field Test of Bricks
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Defects of Bricks
1. Over Burning of Bricks
•This is caused by over-burning due to excess
temperature inside the kiln or burning faces. The
overburnt bricks result in a soft molten mass.
• Not suitable for construction purposes
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Defects of Bricks
2. Under Burnt Bricks
• When bricks are not burnt to complete vitrification,
the clay softens, and pores remain open due to
insufficient heat.
• This results in low compressive strength and high
water absorption, making them unsuitable for
construction work.
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Defects of Bricks
3. Black Core
• It is the presence of circular or semi-circular-shaped
black or grey spots around the core of the fire clay
bricks.
• It is caused by the bitumen or carbon content in the
earthy clay and improper brick burning. Bricks with
this content have reduced strength, low structural
integrity, and reduced load-bearing capacity.
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Defects of Bricks
4. Chuffs
• It is the deformation in the shape of bricks due to the
exposure of hot bricks to rainwater.
• The irregular shape of the bricks could affect the
alignment and interlocking of bricks, weakening the
structural integrity of the structure.
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Defects of Bricks
5. Checks or Cracks
• The bricks are subjected to two types of cracks:
straight and random. Due to rapid drying, straight
cracks occur parallel to the short surface of the brick.
• In contrast, random cracks occur on different brick
surfaces due to lumps of lime and excess water. When
excess water is added to the bricks during
manufacturing, it causes shrinkage and burning
cracks.
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Defects of Bricks
5. Spots
• It is a dark spot on the bricks’ surface caused by iron
sulfide in the clay.
• The spots affect the structural integrity and visual
appeal, making it unsuitable for exposed masonry
work.
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Defects of Bricks
5. Blisters
Blisters in bricks occur on the surface of sewer pipes
and drain tiles. This is due to poor compaction during
the molding process. The air voids imprisoned in the
brick are the main reason for the blistering of bricks.
6. Laminations
It is a defect where a thin lamina is produced on the
surface of the brick, which flakes out due to
atmospheric conditions. The lamination of the brick is
due to the air voids in the clay, resulting in weak bricks.
This reduces the load-bearing capacity and durability of
the bricks in masonry work.
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Brick Masonry
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Brick Masonry
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Brick Masonry
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Bonding in Brick Masonry
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Bonding in Brick Masonry
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Bonding in Brick Masonry
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Bonding in Brick Masonry
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Bonding in Brick Masonry
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Bonding in Brick Masonry
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Bonding in Brick Masonry
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Bonding in Brick Masonry
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Some Important Clay Products
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Some Important Clay Products
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Some Important Clay Products
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Some Important Clay Products
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Some Important Clay Products
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THANK YOU
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