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Brick Manufacture

Brick Manufacture. Carlos Brown, Corey Henriquez, Michael Berry, R.J. Lavigne The Knack 11/30/10. Basic Brick Properties . Clay Bricks are made of Silica, Alumina, Lime, Iron, Manganese, Sulfur, and Phosphates. They are poor conductors and are non combustible.

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Brick Manufacture

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  1. Brick Manufacture Carlos Brown, Corey Henriquez, Michael Berry, R.J. Lavigne The Knack 11/30/10

  2. Basic Brick Properties • Clay Bricks are made of Silica, Alumina, Lime, Iron, Manganese, Sulfur, and Phosphates. They are poor conductors and are non combustible. • Young’s modulus = 1.5 x 106 psi – 5.0 x 106 psi • Modulus of Rupture = 500 – 3800 psi • Density = 125 pcf • Common uses include building, facing, flooring, and paving.

  3. Manufacture Process Overview

  4. Mining and Storage • 3 Types of Clay are used to make Brick • Surface Clays – sedimentary formations found on the surface • Shales – clays subject to high pressures until nearly hardened into slate • Fire Clays – mined at deeper levels than other clays • Mined in open pits then transported to plant storage areas

  5. Manufacture Process Overview

  6. Size Reduction • Dry Pan Crushers- Breaks large chunks of clay or shale • Grinders- pulverizes the clay to a fine consistency (Muller Wheels) • Important to have clays dry when grinding

  7. Screening • Passes through Vibrating Screen, Scalping Screen • Coarse material left goes back to grinder • Hammer mill • Large particles inhibit the durability of the brick

  8. Manufacture Process Overview

  9. Forming • Two steps in the forming process • Tempering • Water is added to the clay in a pug mill • Molding • Stiff Mud • Soft Mud • Dry-Press

  10. Manufacture Process Overview

  11. Drying • The moisture content of the formed clay is reduced, not eliminated, so that the brick will not explode during the firing process. • The clay is sent through a drying chamber for 24 to 48 hours at 100 to 400 deg F. • Heat and humidity must be regulated to avoid cracking in the brick

  12. Manufacture Process Overview

  13. Firing • Tunnel Kiln – Most Common, four stages • Final Drying and Dehydration: 300° F - 1800° F • Oxidation: 1000° F - 1800° F • Vitrification: 1600° F - 2400° F • Flashing: Varies depending on desired color

  14. Cooling and Processing • Tunnel Kiln-10 hours • Rate of Cooling has direct effect on color • Dehacking • Unloading a kiln after cooling • Bricks are sorted , graded, then packaged.

  15. Works Cited • Millberg, M. L. "How Brick Is Made - Material, Production Process, Manufacture, Making, Used, Processing, Dimensions, Industry, Raw Materials, The Manufacturing Process of Brick, Quality Control." How Products Are Made. How Products Are Made. Web. 29 Nov. 2010. <http://www.madehow.com/Volume-1/Brick.html>. • "Brick Manufacturing." Brickwork Design Guide by Glen-Gery Brick. Web. 29 Nov. 2010. http://www.glengerybrick.com/>. • "Manufacturing of Brick." Brick Industry Association - BIA. 2006. Web. 29 Nov. 2010. <http://www.gobrick.com/>.

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