Bricks are made from it. What and how is brick made from?

Brick is an artificial stone made in different ways from clay, sand, lime, cement with the addition of various pigments. Depending on the source material, as well as on the production technology, there are several types of bricks.


The most popular are clinker, decorative, ceramic, silicate, refractory, and facing bricks.

Types of bricks

Ceramic brick is the same classic red stone made from baked clay. This durable and versatile type of brick is widely used in construction, and modern technologies make it possible to get away from the red color and get stone of any other shade. Ceramic bricks can be hollow or hollow, which affects both the characteristics of the stone and its cost.

Sand-lime brick is an artificial stone originally white in color, made by autoclave synthesis from lime and sand. During the production process, the stone can be pigmented. Sand-lime brick differs from ceramic brick in its improved soundproofing characteristics.

At the same time, such bricks are not very resistant to moisture, so the scope of their use in construction is limited.


Refractory bricks are made from fired clay, called fireclay, with the addition of coke or graphite to give the stone greater strength. Such bricks can be carbon, quartz, alumina and lime-magnesium. Chimneys are made from refractory bricks, fireplaces and stoves are built.

Facing bricks are made from cement, with the addition of limestone and pigments. This material is strong, durable, looks great and protects facades well from moisture and temperature changes.

When making facing bricks, pressing technology is used, and this stone is used for finishing facades, restoring destroyed structures, decorating sidewalks, building fences, and so on. Facing bricks do not accumulate dirt and retain their original appearance for decades.

How to choose a brick?

First of all, they focus on the purpose of the stone. Depending on where it is to be used, emphasis is placed on specific characteristics. Manufacturers use special markings to indicate the strength of bricks. The load is indicated per 1 square meter - M100, M200 and so on. The higher the number, the higher the stone’s resistance to deformation.


When choosing a brick, you must also take into account its porosity, frost resistance, density, and thermal conductivity. Density is the ratio of the volume and mass of a brick. Frost resistance is the number of freezing and thawing cycles during which the stone will retain its original strength.

To mark frost resistance, use the letter F and numbers. In residential construction, as a rule, bricks marked F35 are used.

The most popular technologies

If the brick is made by firing clay, then before this process the clay is laid out in a concrete pit and filled with water. After three or four days, the clay is taken out and mechanical processing begins - at the enterprise, stones are removed from the clay composition, thoroughly mixing the mass.

After this, the clay goes into a belt press, where the bricks are cut according to a standard pattern. In a special chamber, the bricks dry under the influence of steam, and then they are sent to a tunnel kiln for firing. If the use of firing is not intended, then the brick is made by pressing.

The mineral components are welded under high pressure using binders and water. The finished substance is kept for up to five days, and after that it is mixed with cement in a concrete mixer. Bricks are then formed and allowed to rest for three to seven days.


There are many ways to improve the quality characteristics of bricks - add fireclay to the mixture, use vacuum pressing, tunnel dryers with recirculation.

It is believed that the highest quality bricks are obtained when fired in kilns running on liquid fuel or gas. Mineral additives and pigments help obtain the desired color. In order to improve the visual characteristics of the brick, its surface is subject to decorative treatment.

There are many advantages that make brick one of the most popular building materials. In addition to standard sizes and simple shapes, this artificial stone boasts strength, durability and beauty, which is why it has been used for a very long time and almost everywhere.

The technologies used to make bricks also deserve attention - as a set of processes that make it possible to obtain a material with all the characteristics the customer needs.

Composition depending on type

Among all types of bricks, the two most popular are ceramic and silicate, also called red and white, respectively.

They differ in the following features.

• The main component of ceramic bricks produced by firing is clay. This material has an aesthetic appearance, dampens noise and perfectly stores heat in the room.
• The composition of sand-lime brick, produced under high pressure and steam, includes sand and lime. Compliance with technology allows us to obtain durable and inexpensive products that can withstand changes in temperature and humidity.

It is also necessary to highlight refractory bricks made from fireclay with the addition of coke or graphite - components that significantly increase its strength.

Another current variety is facing, the production of which involves the use of cement, limestone and a pigment ingredient. Such bricks, made using pressing technology, have not only an aesthetic appearance, but also an impressive service life.

Considering the greatest significance of the red and white varieties, they are worth considering in more detail - which will be done further.

Ceramic

The main ingredient of this type of brick is ordinary clay. It is a mineral mass that:

• becomes plastic when water is added to it;
• keeps the shape during the drying process;
• hardens as a result of firing, acquiring strength comparable to natural stone.

The origin of the clay used deserves special attention. Depending on the depth of its occurrence, it can have different properties - both suitable for brick production and those that do not meet the established requirements.

If we single out the component that most often forms the basis of clay, then it is kaolinite - one of the hydrous aluminum silicates. Also, the raw materials used may include montmorillonite, illite, quartz and other minor ingredients.

In addition to clay, ceramic bricks consist of other components, which are additives. They are used to impart certain properties to manufactured products, and the main ones among them are the following.

• Weakening– ash, sand, slag. Promote better mass formation and less shrinkage.
• Burnouts– sawdust, powdered coal or peat. They increase the porosity of the material, which naturally reduces its density.
• Coloring– usually metal oxides. Give products the required color or shade.

In addition, it is worth mentioning iron ores and sandstone, the use of which allows you to effectively regulate the firing temperature.

Plasticizers can also be used - additives that minimize the likelihood of cracking of the ceramic material. The specific quantity of each of the listed ingredients is determined by customer requirements and/or manufacturer policy.

Silicate

The production of white brick involves the use of three mandatory components, the list of which is as follows.

• Sand. It can be of both natural and artificial origin. It is desirable that the grains used are uniform and have a size from 0.1 to 5 mm. The surface features of the sand grains are no less important (in the presence of sharp corners, they provide better grip). A prerequisite is the preliminary cleaning of the material from foreign matter.

• Lime. To obtain this component, raw materials are used that have a high content of calcium carbonate (90% or more) - primarily limestone and chalk. Before firing at a temperature of about 1150°C, the prepared rock is crushed to a size not exceeding 10 cm. Upon completion of the above procedures, lime is added to the composition of the sand-lime brick (the optimal value is 7%).
• Water. This ingredient is needed to solve two main problems - slaking lime and imparting plasticity to the formed mass. It is used at all stages of sand-lime brick production.

Often, the production of the described products involves the use of additional components necessary to give the product the desired characteristics.

• Chemical compounds. An example is titanium dioxide, thanks to which sand-lime bricks remain white for as long as possible.
• Components that increase frost resistance. Most often, to solve this problem, industrial processed products are used, which reduce the thermal conductivity of the material by 10-12%.
• Dyes. They are used in situations where the manufacturer needs to give products a specific shade or tone.

Expanded clay sand also deserves mention - an additive that can simultaneously solve two problems at once. In addition to a noticeable increase in the thermal efficiency of silicate products, it gives them a beautiful coffee color, which makes them look more solid.

Production technology

Depending on the type of bricks being made, their production has its own characteristics. This is explained by the specifics of the ingredients used, which require the use of various technological processes.

Red

There are two main methods for producing ceramic bricks - semi-dry molding and plastic molding. The latter, which is more popular, involves a step-by-step solution to the following problems.

• Preparation of the main component – ​​clay. It is allowed to include additives in the mixture - no more than 1/3 of its total quantity. In this case, the fraction of the main ingredient should not exceed 1.2 mm.
• Moving the prepared mass for further molding.
• Dividing the total array into standard sizes.

• Drying ceramic bricks.
• Perforation of products (relevant in situations where products need to be made hollow).
• Burning. This type of processing involves a smooth change in temperature in the furnace (first upward, and then vice versa). Following this rule allows you to avoid the appearance of cracks on bricks due to sudden temperature changes.

As for the production of ceramic bricks using the semi-dry molding method, it involves the following procedure:

• preparation of raw materials and their grinding;
• drying and re-crushing;
• slight humidification with steam;
• re-drying;
• removing the last traces of moisture from ceramic products.

It is also reasonable to mention the production of red brick at home: in a similar way, it is quite possible to produce a full-bodied “raw” variety of this material.

To solve this problem it is necessary:

• make a ball from a homogeneous piece of clay, previously moistened with water;
• carefully inspect the sample after 4 days for uneven shrinkage and cracks;
• provided there are no visible defects, the ball must be dropped to the ground;
• If the sample does not pass the strength test, its composition must be strengthened with appropriate additives.

Upon completion of all preparatory procedures, the mixture must be distributed into molds made of wood. The finished ceramic products will be left to dry in the shade, after which they can be used for the construction of light one-story buildings.

To make surfaces more durable, it is advisable to cover them with paint or high-quality cement mortar.

White

One of the main features of the manufacture of sand-lime bricks is its complexity, which does not allow solving this problem at home. In particular, this is explained by the impressive list of necessary equipment - conveyors and conveyors, crushers and dispensers, mixers and autoclaves, cranes and loaders.

There are two main production methods for the products in question – drum and silo.

The technology for manufacturing sand-lime bricks involves the following steps:

• checking and preparing the main components - sand and lime (the first is separated from large inclusions, and the second is crushed);
• mixing components followed by settling in a bunker;
• grinding the mixture and adding water to it;
• lime slaking, carried out in a drum or silo (determined by the selected production method);
• removing moisture from sand;
• molding using a press;
• steam treatment in an autoclave (recommended temperature – 180-190°C, pressure – 10 atmospheres).

At the final stage, the temperature and pressure are gradually reduced. Upon completion of all procedures provided for by the technology, the finished sand-lime bricks are packaged and sent to the customer.

Brick, as the oldest building material, is found almost everywhere; it is universal, beautiful, and durable. Let's try to understand in detail what types of bricks there are, depending on the material of its manufacture, the scope of its application, manufacturing methods and sizes. Its format and composition can be varied; this material has gone through a difficult path throughout the history of civilization.

Brick: brief information about the material

Brick is made from clay. Depending on the type of clay and production method, there are several types of bricks (ceramic, silicate and refractory), which in turn are also divided into subgroups. The most extensive classification of bricks in construction and landscape design of a site consists of 2 types: building bricks and facing bricks.

Construction bricks are used for laying walls and piers. It is, as a rule, cheaper and GOST standards are not so demanding for it. The surface of building bricks can be chipped, rough, stained by salt protrusions and vary in color. After laying the building brick, it is additionally necessary to veneer it, plaster it and paint it to taste.

For facing bricks, GOST requirements are an order of magnitude higher: the material must be uniform, without noticeable color changes, without chips, cracks or irregularities. The facing brick can be shaped, which is what determines its shape - slightly rounded, angular, non-standard shape, etc.

Also, brick, regardless of the type of clay and purpose, can be solid, effective and super-effective, we will also talk about this.

There is a special form of brick - with a chamfer, when the corners of the building material are made beveled. This innovation not only improves the appearance of the brick, but also reduces damage during transportation.

When choosing a brick, special attention is paid to its physical properties: strength, frost resistance, moisture absorption. We will definitely talk about this below.

You should also pay attention to one of the most important components of the appearance of brickwork and structural strength - this is the technology for creating seams, because Too large/small seam sizes will not only spoil the “face” of the structure, but will also make it less stable.

Varieties

As you know, building bricks vary in size, characteristics and purpose. In this case, this material can be divided into 3 categories: One-and-a-half. Single. Double. The size of a standard brick is different for each of these types. It is determined by three parameters: length, width and height. The size of the brick (standard single type), which is used in the construction of most modern buildings and institutions, is as follows: 250x125x65 millimeters.

In this case, the silicate (double) material has dimensions of 250x120x188 millimeters. In construction, the size of a standard brick is 250x125x65 millimeters. That is, the most used type of brick is single. In addition, in the construction industry its thickened version is often used, 250 mm long, 120 mm wide and 80 mm high. It is also worth noting the modular varieties. The dimensions of a single modular brick are 138x13x288 millimeters.

It is worth noting that so-called ceramic stones can also be used in the construction of walls. They have nothing to do with stones, and therefore in production they are labeled as ceramic blocks. Many sellers also refer to them as “double brick,” so when purchasing, do not think that this is a different type of material. Ceramic stone, block and double brick are one and the same product. And its dimensions are as follows: 250x125x138 millimeters (length*width*height, respectively).

What is sand-lime brick made of?

White sand-lime brick is the most popular and inexpensive building material. It contains only environmentally friendly substances. Approximately ninety percent sand-lime brick consists of purified quartz sand, and ten percent water and lime. Depending on the method of its production, the percentage may vary.

Typically, sand that is used to make bricks undergoes very careful processing. It is cleaned of all kinds of clay and organic impurities, since impurities reduce the strength of the product. Lime, which is part of sand-lime brick, must also have a certain chemical composition. For example, the MgO content in lime cannot contain more than five percent. Ground bricks are usually used to create bricks.

Composition of red brick

Red brick has long been recognized as the most reliable and versatile building material. This natural material is created from clay. Depending on the iron content in it, the color of the brick changes. Red bricks are usually made from red-burning clay. If the clay is white-burning, then the brick will acquire an apricot tint. Often certain pigment additives are added to the brick composition.

To obtain high-quality red brick, homogeneous clay is used, which is mined in a fine fraction. The quality of the resulting product depends on the correctly selected components.

What are ceramic bricks made from?

Ceramic or building bricks are actively used for the construction of load-bearing wall structures and interior partitions. High-quality bricks must be made from a constant composition and clay of fine fractions. In the process of proper firing of clay, its refractory elements dissolve. If you follow the correct technology for molding and drying the raw materials, you will get the most durable ceramic brick.

Depending on the components, the brick can be light yellow or dark brown. Nowadays, pigmentation of ceramic bricks is often used to give it certain shades.

Brick size standard

There are single, double and one-and-a-half bricks; we will consider the sizes of each type below.

In the process of development of the construction craft, certain standards have been developed that the material must meet. Single brick size: 120mm wide, 250mm long and 65mm high. It is this size of bricks that is considered ideal for masonry with alternating longitudinal and transverse placement.

Over time and the development of construction, more and more diverse materials were required. This is how new, non-standard one-and-a-half-size bricks appeared. Their parameters are: 120 mm wide, 250 mm long and 88 mm high.

The use of such bricks requires knowledge of a special masonry technique designed to lighten the final weight of the building. So, it is necessary to alternate solid bricks with porous, perforated or hollow ones.

Double brick has impressive dimensions, as a result of which it is never made solid. The brick size is 120 mm wide, 250 mm long and 103 mm high. They are used only for lightweight masonry.

White brick: sizes and applications

White or sand-lime brick is made on the basis of silicate, which is why it got its name. Durable and lightweight material, which is mainly used for the construction of walls and partitions. Such bricks are never used for laying foundations, stoves, pipes, fireplaces or plinths. Standard size of white brick: 250x120x88 mm.

Compliance with GOST GOST

(State standards) do not apply to products of this type in Russia, especially for new technical products that appeared on the market several years ago. Of course, the use of ceramic bricks in the construction of a residential building or other buildings is a very profitable business, since due to its large size the costs of its laying are minimal. Accordingly, the speed of work is many times greater than the time required for laying single material. In addition, the savings also apply to the cement mortar that needs to be prepared for laying a row of bricks.
Ceramic stone is mainly used in the construction of multi-story buildings, be it a residential building or a garage. Statistics show that the number of one-story houses in which this type of material is used during construction is only a few. Although even if we compare the total number of multi-storey institutions with walls made of ceramic stone and the same buildings with classic single brick, the difference will be several dozen times.

Types of bricks and their sizes

When starting to search for a suitable material for cladding or building walls, you should pay special attention to the standards for the edges of the product. This will help you correctly calculate the masonry pitch and select the quantity you need.

There are the following 3 standard brick sizes:

European standards have the following standard sizes:

DF-240x115x52 mm;

2 DF-240x115x113 mm;

NF-240x115x71 mm;

RF-240x115x61 mm;

WDF-210x100x65 mm;

Physical properties of bricks

Strength

The strength of the brick directly affects the stability and durability of the structure. The strength is determined based on the marking of the brick, which is established by the manufacturer using experimental methods - the compressive strength of the material (how many kg will 1 cm2 of material withstand).

It is customary to mark bricks as follows: the letter “M” and the number after it indicate what load the material can withstand: M100, M125, M200, M300, etc.

• For laying the walls of one- and two-story buildings, it is allowed to use M100 brick
• For laying the walls of high-rise buildings, bricks with a strength of at least M200 (preferably M300) are used.
• The foundation must be laid with bricks M150 and higher

It should also be noted that the higher the strength of the brick, the less damage will be caused to it during transportation.

Frost resistance and moisture absorption

The frost resistance index determines how many cycles of sudden temperature changes during the winter season the material can withstand. Frost resistance, like other physical properties of bricks, determines the durability of the material, and, accordingly, the entire structure.

Brick manufacturers use an experimental method to find an indicator of the frost resistance of a material: water-saturated brick is frozen and thawed until it begins to lose its strength properties. Bricks are marked for frost resistance as follows: put the letter “F” and next to it a number indicating how many cycles the brick can withstand and the higher the number, the better its frost resistance, and therefore its durability.

The moisture absorption of brick is also one of the most important physical properties of the material, which is interconnected with frost resistance - the lower the moisture absorption, the higher the frost resistance.

The following GOST standards for moisture absorption of the material have been established:

• Sand-lime brick (or other material to which lime is added) – up to 20%
• Brick made from white-burning clays – up to 6%

It should be noted that the frost resistance index for building bricks should be 15 cycles, and for facing bricks from 25 and above. The frost resistance of high-quality imported bricks can reach “50”, which is a very high indicator.

What you need to know

In terms of its strength characteristics, white sand-lime brick is better than red brick, but due to its poor moisture resistance, it is not suitable for underground masonry; it can be used for cladding the foundation, especially since such a building material has a very presentable appearance.

The only type of brick that can adequately replace red brick in underground work is clinker brick, made from special types of clay. This building material is much stronger and can withstand moisture. However, its high cost makes its use in creating foundations impractical.

Clinker brick belongs to the cladding grades and is used, as a rule, in the process of cladding work on building facades. It is strictly not recommended to use any brand of hollow brick for underground masonry. It perfectly absorbs moisture and is not able to withstand bending and compression loads. It is also not recommended to build a foundation using any brand of sand-lime brick, which is very poorly resistant to temperature changes and is easily destroyed by water, which is not surprising, given the fact that sand-lime brick is essentially pressed sand.

Brick weight

Another characteristic of a brick is its weight. This indicator is completely different for different types of products. Thus, the weight of standard ceramic or sand-lime brick is 3.8-4 kg. Moreover, if the brick has cavities inside, then it will weigh less. Therefore, during design, the weight of each brick is not taken into account, but only the specific masonry, that is, the weight of 1 cubic meter of building material plus the weight of the required amount of cement mortar.

The specific gravity of masonry can vary from 600 kg/m³ to 1800 kg/m³ and directly depends on the weight of each brick. By calculating the weight of the future building at the design stage, you can make adjustments to laying the foundation, thus making the structure stronger and more reliable.

Few people know, but unified brick standards in Russia were introduced just a few years ago - in 2008. And this despite the fact that it first began to be used in 1927. To the surprise of everyone, in Soviet times, almost all buildings were created using bricks that did not meet any standards and requirements. However, it is these buildings that are currently the most durable and wear-resistant.

Making bricks using artisanal methods. DIY brick

Source: building-ooo.ru

Brick of any kind in all reference books and dictionaries is defined as an artificial stone in the shape of a bar. There are several types of this building material, depending on what the bricks are made from and what production method is used.

Based on these characteristics, two main groups can be distinguished:

• Ceramic

This is a classic red brick made of baked clay or a mixture of several types of it.

• Silicate

Made in an autoclave from sand and lime, the color depends on the additives. White brick can be given any color, incl. red, but this will not give it the right to be called red - it will remain silicate red.

Types and quality of bricks

The scope of application of this material is very wide. Red brick is used to build load-bearing and self-supporting walls and partitions in buildings of various heights; it is used to fill the voids of concrete structures, lay foundations, internal parts of furnaces, etc.

Building brick is called ordinary brick, but its front (facing) appearance is more valued. After firing at high temperatures, the material is durable and beautiful, and is widely used for cladding the external walls of buildings and plinths, restoration work and for interior design.

Properties of ceramic bricks:

• Strength and durability.
• Frost and moisture resistance.
• Reliable sound insulation.
• Hydrophobic and quick drying.
• Environmental friendliness. The natural composition of bricks and time-tested technology guarantee the safe stay of people in brick walls.
• High density (with manual molding reaches 2000 kg/m³).

Disadvantages include high cost, which is explained by the complexity of the technology. This material is very durable; houses made from it last hundreds of years. If you want to build a quality building, you should not try to make bricks yourself – It is impossible to ensure a sufficient firing temperature in artisanal conditions.

For cladding, you should buy material from the same batch, otherwise the color may differ.

Types of fired bricks

• Private requires plastering. Often, a pressed pattern is made on its side for adhesion to the solution.
• The front has two smooth surfaces; they also produce textured and shaped types. There are many voids inside to increase thermal insulation.
• Stove and fireclay are made from refractory clay. The material is sand-colored and grainy.

When buying a brick, it is important to understand its purpose. Ordinary brick is much cheaper than face brick and there is no point in overpaying for the construction of walls.

Basic composition and properties of clay

The useful properties of the material directly depend on what the brick is made of and how accurately the technology is followed. A high-quality product can be obtained by supplying clay with a constant composition and uniform production operation.

The facial variety is made from fine clay. There are few rich deposits with a uniform mineral composition left. In most cases, mining is complicated by multi-layers of clays of different compositions. The layers are cut off with an excavator, the clay is crushed and mixed until an average composition is obtained. This is necessary for uniform drying and firing, since clay of different composition requires individual thermal and time processing conditions.

Typically, an enterprise works with raw materials from one deposit, so the right technology allows them to obtain a high-quality product for many years. When exploring and developing new deposits, the quality and quantity of clay is analyzed. The best red brick is obtained if the clay composition does not require additives. Typically, clay is suitable and cannot be used to produce other ceramic products.

When water is added, the mineral mass becomes plastic, and after drying it retains its shape. After firing, the clay hardens and becomes very durable.

For the production of red brick, raw materials are suitable, which include:

• Kaolinite
• Illit
• Montmorillonite
• Quartz

Important properties of clay for making bricks:

1. Plastic. The clay should not collapse when kneaded and retain its shape. Plasticity can be high, medium, moderate and low. Non-plastic clays are also found.
2. Bonding ability. The raw material retains its plasticity after adding additives. It varies as a percentage of the amount of sand and can be in the range from 20 to 80%.
3. Shrinkage. Changes in size after drying and during firing.
4. Caking ability. The property of hardening when heated. Low-temperature clay is sintered at temperatures up to 1100 ° C, medium-temperature clay - 1100-1300 ° C, high-temperature clay - more than 1300 ° C.
5. Fire resistance. When heated, the raw material should not melt. The highest fire resistance is found in pure, highly plastic kaolinite clays, from which porcelain is made. The facing type is made from refractory raw materials with a small amount of impurities. For ordinary bricks, a fusible type is sufficient.

Supplements

Without additives it is impossible to achieve high quality material. The technologist who draws up the recipe and knows how to make brick according to GOST, provides ways to improve the quality of the raw material.

The following additives are used:

• Slag, sand, ash.

Added to thin the raw material, facilitate formation and reduce shrinkage.

• Sawdust, coal and peat powder

Organics are added to reduce density. After the additives burn out, they leave pores.

• Iron ore, sandstone

Special additives for regulating the firing temperature.

• Ulphite-alcohol stillage

Makes molding easier.

• Metal oxides

Gives color.

The technologist’s task is to select the optimal composition of raw materials, molding, drying and firing modes.

Color

You can achieve the desired color not only with the help of additives. In most cases, it all depends on the mineral composition of the clay, which is redder after firing. This type of clay is called red-burning clay.

Quite rarely, white, yellow and apricot-colored ceramic bricks are made from white-burning clay.

The brown color is obtained after adding pigments.