Bricks Notes for AL Tech by Hafeel Sir

8/21/2019 Bricks Notes for AL Tech by Hafeel Sir

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Brick Masonry -

History, types, manufacturing and properties.

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History


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History of Bricks: Bricks are one of the oldest types of building blocks.

They are an ideal building material because they are relativelycheap to make, very durable, and require little maintenance.

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A brickis a block of ceramic material used in masonryconstruction, usually laid using various kinds of mortar.


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History of Bricks: Bricks dated 10,000 years old were found in the

Middle East.

Examples of the civilizations who used mud brick

are the ancient Egyptians and the Indus ValleyCivilization, where it was used exclusively. Inparticular, it is evident from the ruins of Buhen,Mohenjo-Daro and Harappa.

The first sun-dried bricks dpy; were made in Mesopotamia (what is now Iraq), inthe ancient city of Ur in about 4000 BC


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After the foundations have been completed the

walls are set out and construction commences.


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Walls

Walls can be classified in a number of ways:-Solid

Cavity

Internal

ExternalLoad bearing or

Non load bearing

Load bearing supporting roofs, f loors etc.

Non load bearing Dividing spaces


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Main functions of walls

1. Strength

2. Stability

3. Weather exclusion4. Thermal Insulation

5. Sound Insulation

6. Durability

7. Fire resistance

8. Appearance

Part of a cavity wall with the internal

skin removed to expose theInsulation


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Bonding of Brickwork / Blockwork

Bonding of brickwork is thearrangement of brickwork in a wall,

column or pier which will give maximum

overlap and no continuous vertical

joints. The purpose of bonding is to:-

1. Obtain maximum strength whilstdistributing the loads carried by the

walls.

2. Ensure lateral stability andresistance to side thrusts.

3. Create an acceptable appearance.

LOAD

Possible settlement

Unbonded walls Comparatively weak and liable to fail under load or lateral

thrust.


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Bonding of Brickwork / Blockwork

Bonded wall

load isdistributed over the whole

wall and has greater

resistance to side thrust.Standard brick sizes

Length + one mortar joint =225mm

Width + one mortar joint =112.5mm

Height + one mortar joint =75mm

Mortar joint thickness = 10mm

LOAD

SPREAD OF LOAD


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13

Header

Row lock

Stretcher

Soldier


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Brick position


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Technical terms used in brick masonry

Header

Brick which is laid with its length perpendicular to the face of thewall.

StretcherFull brick which is laid with its length parallel to the face of the wall.

CourseHorizontal layer of brick.

Header courseCourse of brick work fully composed of header

Stretcher course

Course of brick work fully composed of stretchers.


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Half bat Queen closer

King closer


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CloserPortion of brick cut in such a manner that one long face remains uncut.

King closerBrick is cut in such a way that the width of its end is half of full brick.

Queen closerBrick is half as wide as a full brick.

Half BatPortion of brick cut half across the width.

Bevelled closerIt is similar to king closer with the only difference that the whole length

of he brick is bevelled.


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Brick Bond: Bond the arrangement of bricks in rows (courses).

Bonds are designed for:

Appearance To tie together a structural or outer wall (wythe)to an

inner wall

Wythe a vertical section of wall one brick thick


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Brick Work

Brick laying Material that was used in

mortar (mix of cement orlime with sand or both

Ratio; binder : sand = 1:3

Thickness or mortarnormally in range 6.5mm -9mm

20


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Brick Work Brick lying finishing: Normally, brick lying will followed by

brick lying finishing. The objective is to get good appearanceor good finishing to brick lying joint.

It can be make slowly without fully complete or after itcomplete

21Mortar

dikemaskan

Mortar lebihandikeruk & di buang

sedalam 15mm


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22

Masonry Joints

Concave

Flush

Racked

Struck

Weathered

Vee


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Brick workBrick arrangement in

brickwork Some of the popular brick

arrangement is:

Brick edge Arrangement

Brick headArrangement

American Arrangement

English Arrangement

Flemish Arrangement

23

American

Arrangmen

t


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Stretcher Bond

This is the simplest and most widely used bond. Itis used for half brick walls and cavity walls. Thebricks must lap over each other in successivecourses in a fashion similar to the one shownbelow.

Half lapped


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Formation of a corner in stretcher bond bat to formstopped end

Racking-back


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Wall tie

Quoin

Cavity

D.P.C.

Horizontal

mortar joint

Perpendicularmortar joint

Return corner of a cavity wall in stretcher

bond including wall ties and DPC


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Header course

Stretchers course

Queen closer

ISOMETRIC VIEW OF

ENGLISH BOND


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ISOMETRIC VIEW OFFLEMISH BOND

Header

Stretcher


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Advantages of bricks :

Brick will not burn, buckle or melt.

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Brick will not rot and allow Termites to invade.nrq;fy;ypDy; G+r;rp Gof;fs;Jisf;fhJ

Brick will not rust and corrode.nrq;fy;yhdJ ,yFtpy; JUNth , JhshfNth khwhJ

Brick will not fade from the Sun's UV Rays.#upa xspapdhy;ghjpf;fg;glhJ

Brick will not be damaged by high winds, rain or hail.


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Brick will not require constant maintenance.

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Brick will not limit your personal expression.

* Brick will not limit your design options.


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General Characteristics of Bricks

Brick is made of clay or shale formed, dried and fired into

a durable ceramic product.

There are three ways to form the shape and size of a brick:

Extruded (stiff mud), Kiwik

Molded (soft mud) Kiwik

Dry-pressed. Kiwik

The majority of brick are made by the extrusion method.


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Brick achieves its color through the minerals in thefired clay or through coatings that are applied before orafter the firing process. This provides a durable colorthat never fades or diminishes.

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Brick shrink during the manufacturing process asvitrification occurs.

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The method used to form a brick has a major impact onits texture.

Sand-finished surfaces are typical with molded brick.

A variety of textures can be achieved with extruded brick.

Brick manufacturers address sustainability by locatingmanufacturing facilities near clay sources to reducetransportation, by recycling of process waste, by

reclaiming land where mining has occurred, and bytaking measures to reduce plant emissions. Most brickare used within 500 miles of a brick manufacturingfacility.


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Raw material for clay:

Clay is one of the most abundant natural mineralmaterials on earth. For brick manufacturing, clay mustpossess some specific properties and characteristics.

Such clays must have

plasticity,which permits them to be shaped or moldedwhen mixed with water; they must have

sufficient wet and air-dried strength tomaintain their shape after forming.

Also, when subjected to appropriate temperatures, theclay particles must fuse together.


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clay are composed of

silica

aluminawith varying amounts of metallic oxides.(particularly those of iron, magnesium and calcium)


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B i k


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Bricks Manufacture - 4 stages

Material preparation Manufacturing drying Firing

Preparation: material

(clay) washed and grinding(fineness)

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Sample of grinding machine

for clay

Sample of crushing machine

B i k


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Brick Manufacturing: Clay will

grinded with 15% of water. Theclay will be pushed through themould base on the shape. Afterthat, Clay will cut to get astandard size of brick using wire.

Sometimes, bricks will producedusing big mould that clay will bepress that using hydraulicmachine (This method, clay willgrind 10% of water) or withouthydraulic press (with 30% of

water)

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After bricks in form,

identification orperforation to the bricks.

Drying :Wet unit brickswill be drying in space or

room with controltemperature to make surethe bricks in complete dry.

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Brick was compile

before bring to the

kiln


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Firing: Dry bricks, wascompile in kiln to firingprocess with 600oC(temperature). This is forburn the carbon and sulfurthat have remain.After

that, temperature willincrease to 900oC to get a

vetrification process.

Normally, vitrification

process occurred around800oC.

Bricks become hard/strongafter vitrification process.

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B i k


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Bricks

Bricks manufacturing process

flow


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MATERIAL PREPARATION


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Manufacturing


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Manufacturing


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Setting


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Firing Process


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Packaging

PROPOERTIES OF BRICKS


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PROPOERTIES OF BRICKS The most important properties of brick are

1) durability -

2) color -

3) texture -

4) size variation -

5) compressive strength -

6) absorption. -


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Durability:

The durability of brick depends upon achievingincipient fusion and partial vitrification during firing.

Because compressive strength and absorption values arealso related to the firing temperatures, these properties,together with saturation coefficient, are currently takenas predictors of durability in brick specifications.

However, because of differences in raw materials andmanufacturing methods, a single set of values ofcompressive strength and absorption will not reliablyindicate the degree of firing.


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Texture:

Coatings and Glazes : Many brick have smooth or sand-finished textures produced by the dies or molds used informing.

A smooth texture, commonly referred to as a die skin

results from pressure exerted by the steel die as the claypasses through it in the extrusion process. Mostextruded brick have the die skin removed and thesurface further treated to produce other textures usingdevices that cut, scratch, roll, brush or otherwise

roughen the surface as the clay column leaves the dieBrick may be tumbled before or after firing to achieve anantique appearance.

Color:


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Color:

The color of fired clay depends upon its chemical composition,the firing temperatures and the method of firing control.

Of all the oxides commonly found in clays, iron probably hasthe greatest effect on color. Regardless of its natural color, claycontaining iron in practically any form will exhibit a shade ofred when exposed to an oxidizing fire because of the formationof ferrous oxide. When fired in a reducing atmosphere, thesame clay will assume a dark (or black) hue. Creating areducing atmosphere in the kiln is known as flashing orreduction firing.

Given the same raw material and manufacturing method,

darker colors are associated with higher firing temperatures,lower absorption values and higher compressive strength

values. However, for products made from different rawmaterials, there is no direct relationship between strength and

color or absorption and color.

Size Variation


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Size Variation

Because clays shrink during both drying and firing,allowances are made in the forming process to achieve the

desired size of the finished brick. Both drying shrinkage andfiring shrinkage vary for different clays, usually falling withinthe following ranges:

Drying shrinkage: 2 to 4 percent

Firing shrinkage: 2.5 to 4 percent

Firing shrinkage increases with higher temperatures, whichproduce darker shades. When a wide range of colors isdesired, some variation between the sizes of the dark andlight units is inevitable.

To obtain products of uniform size, manufacturers controlfactors contributing to shrinkage. Because of normal

variations in raw materials and temperature variations withinkilns, absolute uniformity is impossible. Consequently,

specifications for brick allow size variations.


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Compressive Strength and Absorption

Both compressive strength and absorption are affected

by properties of the clay, method of manufacture anddegree of firing.

For a given clay and method of manufacture, highercompressive strength values and lower absorption

values are associated with higher firing temperatures.Although absorption and compressive strength can becontrolled by manufacturing and firing methods, theseproperties depend largely upon the properties of the

raw materials.


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Tests on bricks:

Clay Masonry Units -ASTM C 67, Standard Test Methodsfor Sampling and Testing Brick and Structural Clay Tile

These test methods cover

Procedures for the sampling and testing of brick and

structural clay tile.

Tests include modulus of rupture, compressive strength,absorption, saturation coefficient, effect of freezing andthawing, efflorescence, initial rate of absorption and

determination of weight, size, warpage, length change, andvoid area.

Brick Work


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Brick Work

Brick shape in

brick work To produce the

variety ofarrangmenet or

special purposein brick work

59

Brick Work


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Brick Work Brick shape in

brick work

60

Angle

Brick

Brick Work


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Brick Work Brick shape in

brick work

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Brick Work


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Brick Work Brick

arrangement inbrick work

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Brick work


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Brick work Brick


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Brick Work


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Brick Work Brick


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Brick Work


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Brick Work Brick


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Brick Work


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Brick Work Plastering

These have been done after brick lying finishing. Thepurpose is to get a smooth surface and uniformity in color.The wall should scratch to get a rough surface that willeasy when plastering work

Materials that was used : lime, cement Portland, gypsum

Plastering work should be in two layers, which one baselayer and finishing layer.

Base layer ; cement :Lime : sand = 1:2:8-9 @ 1:1: 5-6 @cement : sand = 1:3 @ gysum : sand = 1:1-3 @ gypsum : lime: sand = 1:3:7-9

Finishing layer; lime : gypsum = 1: 0.25 - 0.5

66


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Photo advantages of brick

67

Decorative of brick work

Walk way


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68

Photo advantages of brick


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TheEnd

69


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Brick Bond: Bond the arrangement of bricks in rows (courses).

Bonds are designed for:

Appearance

To tie together a structural or outer wall (wythe)to aninner wall

Wythe a vertical section of wall one brick thick

T t b i k


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Test on bricks

To know the quality of bricks following 7 tests can beperformed. In these tests some are performed inlaboratory and the rest are on field.

1. Compressive strength test

2. Water Absorption test

3. Efflorescense test

4. Hardness test

5. Size, Shape and Color test6. Soundness test

7. Structure test


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Compressive strength test

Compressive strength test:This test is done to knowthe compressive strength of brick. It is also calledcrushing strength of brick. Generally 5 specimens of

bricks are taken to laboratory for testing and testedone by one. In this test a brick specimen is put oncrushing machine and applied pressure till it breaks.The ultimate pressure at which brick is crushed is

taken into account. All five brick specimens are testedone by one and average result is taken as brick'scompressive/crushing strength.

W t Ab ti t t


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Water Absorption test

Water Absorption test:In this test bricks areweighed in dry condition and let them immersed infresh water for 24 hours. After 24 hours of immersionthose are taken out from water and wipe out withcloth. Then brick is weighed in wet condition. Thedifference between weights is the water absorbed bybrick. The percentage of water absorption is thencalculated.

The less water absorbed by brick the greater itsquality. Good quality brickdoesn't absorb more than20% water of its own weight.
http://www.acivilengineer.com/2013/05/good-quality-brick.htmlhttp://www.acivilengineer.com/2013/05/good-quality-brick.html


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Efflorescense test Efflorescense test:The presence of alkalies in bricks is

harmful and they form a gray or white layer on bricksurface by absorbing moisture. To find out the presence ofalkalis in bricks this test is performed. In this test a brick is

immersed in fresh water for 24 hours and then it's takenout from water and allowed to dry in shade.

If the whitish layer is not visible on surface it proofs thatabsence of alkalis in brick. If the whitish layer visible about10% of brick surface then the presence of alkalis is inacceptable range. If that is about 50% of surface then it ismoderate. If the alkalis's presence is over 50% then thebrick is severely affected by alkalies


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Hardness test

Hardness test:In this test a scratch is made on bricksurface with a hard thing. If that doesn't left any

impression on brick then that is good quality brick.


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Size, shape and color test:In this test randomlycollected 20 bricks are staked along lengthwise,widthwise and heightwise and then those are

measured to know the variation of sizes as perstandard. Bricks are closely viewed to check if its edgesare sharp and straight and uniform in shape. A goodquality brick should have bright and uniform color

throughout.


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Soundness test

Soundness test:In this test two bricks are held byboth hands and struck with one another. If the bricksgive clear metallic ringing sound and don't break then

those are good quality bricks.


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Structure test

Structure test:In this test a brick is broken or abroken brick is collected and closely observed. If thereare any flows, cracks or holes present on that brokenface then that isn't good quality brick.


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Tools used

Trowel

Plumb bob

Hammer

Spirit level

Mason square

Steel tape


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Mason Square


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Plumb Bob


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Steel tape


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Masonry Joints

Concave

Flush

Racked

Struck

Weathered

Vee

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Bricks Notes for AL Tech by Hafeel Sir

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