One of the essential materials that is frequently used in home construction or renovation is clay. For centuries, clay has been used in construction, especially to make bricks. However, what precisely is in the clay used to make bricks? Comprehending this vital element can significantly influence the resilience, insulating properties, and general caliber of the bricks employed in your residence.

In its most basic form, clay is a kind of soil that is high in water, alumina, and silica minerals. Clay’s special qualities—which include being pliable when wet and robust when dry—come from these minerals. But not all clay is made equally. The geological history, location, and presence of other materials can all affect the composition of clay.

The final characteristics of bricks are largely determined by the composition of the clay used in their production. Different mineral ratios in the clay mixture can have an impact on the bricks’ strength, color, porosity, and thermal conductivity. For example, bricks with higher silica content may be stronger, and bricks with higher alumina content may be better able to withstand heat.

Furthermore, the process of preparing clay for brick-making involves careful consideration of its composition. Clay needs to be refined, usually through a process called pugging, where it"s mixed, kneaded, and de-aired to achieve uniformity and remove any impurities. This refined clay is then molded into bricks and fired in kilns at high temperatures to solidify their structure.

Comprehending the composition of clay used to make bricks is crucial not only for architects and builders but also for homeowners who want to make sure their homes are long-lasting and energy-efficient. Understanding the components of bricks used in building allows one to make choices that improve a home’s overall comfort and sustainability.

Component	Percentage
Clay	60-80%
Sand	20-40%

Drying the brick correctly

To ensure that the outer layer stays moist for a long enough time, the drying process needs to be prolonged. It may warp or crack if it dries much more quickly than the core. As a result, the blocks must not be left outside in the sun or in a draft. A drying shed is the ideal location for drying.

It is kept tightly closed for the first three days, after which doors or windows are opened to allow for ventilation. Drying outside on a wooden board or a mound of dry sand was permitted in good weather, as long as the temperature didn’t drop below +100C. It was also required to be done under a canopy. Depending on the weather, this process may take five to twenty days.

Eight rows is the maximum height for the first laying (six rows is the ideal number). In this instance, there is a space between each row of blocks, and a sand or sawdust backfill is placed in between. Bricks can be arranged vertically on the peck in the bottom row.

Freshly molded bricks are stacked on top in new rows once the material has sufficiently strengthened. Eventually, the entire batch will dry at the same time because the top of the tab dries faster than the bottom.

Although raw, or dried clay brick, is already suitable for use in construction, its instability to moisture limits its use to interior partitions, foundations (provided they have adequate waterproofing), and the inner portion of external walls. The raw material needs to be fired in order to be made into a real brick by hand.

Prior to doing this, the blocks’ condition should be examined. If a block broken in half, taken from the middle of the laying, does not show a dark spot—a telltale sign of still-wet material—the batch is considered ready.

Proportions of refractory concrete

Concrete mixer scheme for mixing concrete.

When the ratios are followed, the mixture—which is frequently used to build fireplaces—can withstand temperatures as high as 1200ºC. The fireplace as a whole or just the fuel-box could be constructed with this mortar.

One part of concrete with a grade of no less than 400, two parts of refractory brick crumbs and sand, and 0.33 parts of chamotte dust-like additive are required.

The following ratios of mortar are needed to create a monolithic hearth and use an eternally open fire there: One part concrete, two to three parts red brick rubble, quartz sand (or red brick that has been finely ground), and 0.33 parts fireclay sand.

Molding stage

The first step in creating clay bricks is casting the billet, which requires preparing molds out of rolled steel or wooden blocks. The inner space of the mold should measure 260x130x75 mm in order for the final product to have the most hand-friendly dimensions of 250x120x65 mm. This allowance results from the clay’s shrinkage during the firing and drying processes.

The mold’s interior needs to be smooth. The mold can be placed in the shape of a frame on a level surface without the bottom having to be attached. Bricks will have notches left in them if tapered spikes are fixed on the bottom or used as the base. It will be held firmly on the mortar because of them.

Sand or sawdust must be added to the mold’s bottom prior to molding, and chalk mortar, oil, or dry cement dusting must be applied to the walls to prevent clay bricks from sticking to the mold.

Tamping clay in the molds has to be done by hand because it is not practical to buy the equipment (special presses) needed to produce bricks from clay in small batches. Care should be taken during this process to ensure that the clay fills in all the crevices thoroughly. Next, the mold is taken out and the extra raw material is removed using a lath to form the top edge.

Advice: You can make the mold foldable to facilitate the removal of the molded clay bricks. It is also possible to cast a sizable portion at a time, which will subsequently be divided into separate blocks and soaked in water using a stretched wire or metal plate.

Wilting occurs when freshly cast, handcrafted clay bricks are left to stand for a couple of hours. Just raise the block by holding it with your fingers to see if it’s ready. The next step, drying, can start if there are no indentations.

How to correctly determine the proportions of additives in the clay for homemade brick

The experiment should be carried out in order to confirm that the clay has the required plasticity and to confidently move forward with producing bricks on their own (and who said that it will be easy and simple?). But only if preliminary testing indicates that sand needs to be added because the clay is oily. You should find a fat clay and combine it with your blanks if the clay is too thin. Regardless, the ratios of the additives must be determined.

Sand, fireclay (Ottoman additives), sawdust (burnout additives for fired bricks), and straw (for adobe bricks) are the additives most frequently used in artisanal production.

Experience will have to be used to determine the mass’s additive composition and proportions. To achieve this, we divide the same volume of clay into multiple portions and adjust the additive ratios accordingly.

It’s crucial to remember to record the proportions used and avoid confusion in this situation. Each sample must then be kneaded, adding water until it reaches a plastic state.

We create a ball and a cake from every sample. The samples that did not survive the drying process and cracked after several days of natural drying have not advanced past the first round of selection. The mixture is excessively oily. The samples that did not crack during drying are thrown onto the ground from a height of one meter in the second round. The clay in the samples that didn’t pass the strength test had an excessively low fat content. You can use samples that have passed mechanical strength and drying tests as a reference to determine the percentage of additives.

The following articles in the block "Brick with your own hands" provide information about how each type of brick is made. Teplostroy construction company reminds readers that any work done by the team will proceed more quickly. An insulated home that is always warm, comfortable, and eco-friendly.

Technological process of brick production

When the clay’s admixture is uniform, the brick produces excellent results and is utilized as a face brick. It is taken out of the clay quarry in deposits where the makeup of the impurities is uniform. The clay from the quarry is put into the concrete creation pits, leveled, and then water is poured on top. This is the firing method used to produce bricks. The clay is then left for three or four days. After the clay has been properly prepared, it is transported to the factory to undergo machine processing.

The clay is fed into a box feeder after being treated with specialized rollers designed to remove stones. The clay is then completely ground once it emerges from the machine’s apertures and is pushed out by unique, movable rakes that push it onto runners. It travels via pliable rollers and onto a belt press, where a specialized cutting device creates the finished clay ribbon. The bricks, which are still wet after being cut, proceed to the wood lining frames and are then put in a drying chamber.

So what to do

Masonry uses a specific type of clay mortar. Few of you have actually used it, but many of you have heard of it and some of you have even seen it. I will therefore describe its peculiarities to you.

Since the so-called fat samples of this kind of mixture only slightly crack when they dry out, I suggest using them. You cannot avoid this because you will fail to reach the highest level of acceptable consistency. In this case, there is no standard; all we can do is keep trying to approach the ideal.

The website dizainvsadu.ru

It is not appropriate to use regular clay that you found by your parents’ house; instead, use fire-resistant clay. In the past, this was utilized to create dishes that solidified through kiln heat treatment. In its natural state, it is fairly hard and has a light brown color. To avoid falling for subpar raw materials, check with friends who have dealt with a similar issue before making a purchase regarding the location.

A bit higher I recalled well-meaning people who are unaware of this problem. I have read articles on multiple occasions saying that ordinary mortars can be used to build chimneys. This is accurate, but only in its most superficial form. Everything needs to be treated precisely with the clay kind, 1.5 meters away from the area where the fire is concentrated. I will discuss the repercussions at a later time.

Thousand-year history

How it all began

The earliest bricks date back more than ten thousand years, if we take into account that they were made in ancient Egypt from bars of dried clay mud. The Egyptians packed it firmly into wooden frames and allowed it to dry outside away from the sun.

Even back then, handcrafted building stones attempted to provide strength and a uniform shape to aid in masonry. Straw or pebbles were added to the mass for this reason.

In many other nations, raw bricks were and are still produced in a manner similar to this one. The word "adobe," which was once used to construct homes in the villages, is well-known to the locals.

A short while later, the raw brick discovered how to be fired in similar raw brick kilns. The material was utilized to build palaces, temples, towers, and fortress walls because of its much greater strength, durability, and resistance to moisture.

This is fascinating. Ancient buildings such as the Pantheon and the Temple of Minerva were constructed using fired bricks.

Brick production in Russia

The history of brick technology development in our nation is linked to Russia’s baptism and the introduction of Byzantine culture. If wood was our ancestors’ primary building material before then, the state started to see the emergence of brick buildings in the tenth century, thanks to a manufacturing technique they had adopted from the Byzantines.

Russian artisans swiftly acknowledged the novel substance and started to refine it. Under John III, the Moscow Kremlin and a number of churches situated on its grounds were constructed from it. But for several centuries, the process of making it has remained largely unchanged: handmade bricks were first air-dried before being fired in raw brick kilns made of raw materials. It was only feasible to complete this task during the summer, for apparent reasons.

The initial Kremlin in Moscow

It was not until the 1800s, during the reign of Peter the Great, that large-scale brick production utilizing labor automation was initiated. At this point, clay mills, ring kilns, belt presses, and other equipment for processing clay had been invented.

As a point of reference. The bricks produced at that time weighed roughly 4 kg and had dimensions of 267x134x67 mm (6x3x1.5 versts).

Clay mortars for masonry furnaces

It is best to use mountainous sand for masonry if you live close to a mountainous area. Contrary to popular belief, river sand is not a better material for construction.

The shape of river sand grains is rounded, that much is true. This property makes them stick to clay less well.

Prior to making the solution, the sand needs to be sieved in order to remove small stones, twigs, plant roots, and other debris from the clay.

After that, the clay needs to be submerged in water in a container for approximately a day in order for it to get soft and plastic.

Sand to clay is typically mixed in a ratio of 1/2. It has two parts sand and one part clay. However, this ratio may change based on the clay’s fat content. The more sand added, the greasier the clay.

Finally, keep in mind that the completed clay mortar can only be stored under a roof or shed. The mortar will be washed away if it rains.

Furthermore, financial factors shouldn’t be disregarded. The cost of the clay castle, constructed with blue clay from the drugstore, will likely exceed that of the house.

Therefore, the best kind of clay mortar will be chosen to minimize expenses and maximize operating time.

Brick molding

Blueprint for building adobe walls.

Pure clay is extremely uncommon in the natural world. It is filled with a variety of impurities, mostly sand. As a result, it can be both plump and, conversely, thin. Prior to anything else, you must determine what kind of material you actually have available. There are multiple approaches to this, but the most straightforward—grandfather’smethod—hasbeen tried and tested numerous times.

Using a bit of clay, you can knead a type of clay dough by gradually adding water to it. similar to how a housewife prepares food. Stop adding water as soon as the dough begins to stick to your hands. Next, you have to shape it into a small ball for ping-pong and a flat mold that is about the size of a tea saucer.

For a few days, this mold and ball should be left in a shaded area to dry. These samples are composed of fat clay if they start to crack. You should try it again with more sand added. Place the ball on the ground so that it is roughly chest high. It will need to have fat added to it if it crumbles because it is too thin. After a few of these tests, you will be able to determine the precise ratios needed to use premium clay to make bricks.

Wet the inside walls of the mold with a little water, then lightly dust them with cement. Then, it will make removing the pre-molded blanks simpler. Once the mold has been filled with clay dough, it needs to be thoroughly shaken. All of the spaces, particularly the corners, must be filled with the raw material. Using a trowel or any handy iron strip, excess mass is removed from the top and pressed down with a lid.

The filled mold is allowed to set for a while, allowing the mass inside to slightly solidify. After that, the mold itself needs to be carefully turned over after the lid has been removed. It will create a molded, ready brick.

Returning to the contents table

What kind of clay is used to make bricks?

Not every clay can be used to create ceramic stones. The substance known as "brick clay" is suitable for use in this kind of production. These clays come in a wide variety, and each one has a unique composition and set of properties.

Properties of brick clay

The following characteristics of clays that make them suitable for making bricks:

• compressive strength (cohesiveness) – at least 3 kgf/cm2
• plasticity
• fusibility
• tensile strength – at least 0.8 kg/cm2
• swelling ability – increase in the initial volume by at least 4%
• ability to form a viscous mass
• stickiness
• ability to retain its raw shape after firing
• refractoriness – at least 1100 degrees Celsius
• sintering temperature – from 1000 degrees Celsius

Clay used to make bricks

All of these markers identify the chemical makeup of the clay used to make bricks; actually, the characteristics of the individual minerals that comprise the composition play a major role.

Apart from kaolinite, the primary ingredient, this

• The mineral montmorillonite, which has the ability to swell strongly;
• silicate minerals called hydrous mica;
• iron oxides, the concentration of which determines the color of the clay;
• quartz.

Three groups can be distinguished when discussing substance fractions. The finest particles are those made of clay, with a dispersion of less than 0.005 mm. Subsequently, there are dusty particles ranging from 0.05 to 0.65 mm and sand particles ranging from 0.05 to 2 mm.

Be aware that while the proportion of particles may vary, a clay composition deemed appropriate for brick production can only be defined as having a clay modulus of at least 0.11. It is the proportion of clay-containing materials to all of the sand and dust combined.

It is called loam if there is more sand than clay, and sandy loam if there is more sand than clay.

Areas of application

In addition to ceramic bricks, brick clay is used to create clinker bricks, facing tiles, slotted blocks, ventilation facade panels, and tiles. Additionally, it is used to make expanded clay, or agloporite, which is a lightweight ceramic aggregate for concrete that is produced by firing clay granules for a brief period of time in rotary kilns.

You can see only a tiny selection of goods created using brick clays in the photo selection below.

Ceramic wall panel

Panels on the facade with ventilation

Claydite: an insulator and concrete filler

• Brick clay is used as an additive in the production of lime-clay and pozzolanic cements.
• Clays with a high content of iron oxides, which have a mottled color, are included in the composition in the manufacture of mineral paints.
• They are used alone, or in combination with cement, as a binding agent in masonry and plaster mortars.
• And also, from brick clay make clay bricks with their own hands, which, although inferior to factory products in appearance, but have enough strength to build a house or lay a stove from them.
• Brick clay is also used for laying clay bricks. However, if it is not a furnace, but exterior walls, it is still better to favor the traditional cement mortar.

Masonry cement made of clay

Note: After covering the walls with roll waterproofing, it is preferable to cover the exterior of the masonry composed of adobe bricks, regardless of whether it is constructed with clay mortar, bricks or tiles, polymer-cement plaster, or just wagon or siding. Only places with a predominantly dry and hot climate are suitable for clay cladding. Persistent moisture can allow the clay to seep in.

You can prepare the raw materials needed to mold red clay bricks at home by following the directions in the upcoming chapter.

Firing

The steps involved in firing bricks are as follows:

1. Blocks are dried at a temperature of about 1500C for 2 days. It is necessary to reach this temperature gradually, otherwise the steam, which is formed in large quantities, will break the blocks.
2. Then the actual firing begins. The firing temperature is 850-10000C, and it should be set smoothly. The firing stage lasts three or four days. Sufficient temperature can be determined by eye – by light yellow or yellow-orange color.
3. The final stage is smooth cooling. While the fuel is burning out, the stove should be completely bricked up to prevent cold air from getting in: the gaps formed are sealed with clay, the firebox is covered with bricks and also sealed with plaster. The cooling process should take at least 2 days.

After the kiln has cooled, the bricks inside are examined to ensure they have been fired to a high standard. If you hit it with a hammer or another light metal object, it should normally ring. If the block muffles sound, it should be sent back for firing or, under certain conditions, used as regular raw material to build interior partitions and other moisture-resistant structural components.

In contrast to a heating oven, a firing oven is constructed without the use of thermodynamic tricks, so an expert furnace builder is not required for this purpose. Whether it is raw or fired, the substance is the same: clay brick. The walls are 50 cm thick at the bottom (or two thirds of the height), and then another 25 cm thick.

A large barrel (200-250 liters) set on 20-centimeter legs in a half-meter-deep pit can hold a small amount of bricks for firing. To keep cold air out of the barrel, the top is covered with a metal sheet and the bottom must be cut out. Initially, though, bricks are piled in the container one on top of the other, with tiny spaces between each stack.

For 18 to 20 hours, keep the fire going in the pit beneath the barrel. To guarantee gradual cooling, it should then be smoothly lowered. Only after the barrel has cooled down completely, about four to five hours, can the lid be removed.

As you can see, the average person without specialized equipment can easily access the technology used in the production of clay bricks. Recall that only one-story buildings can be constructed using homemade blocks.

How to choose the right fireclay brick

For the stove, the brick needs to be uniform, free of dents, scratches, and white patches, and the right shape. The brick is typically 230x114x65 in size.

Refractory bricks range in color from creamy sandy to light brown, almost white. The brick is more appropriate for laying the stove’s fuel box if it is darker and richer in color.

Brick should be uniform, smooth, free of dents, scratches, and cracks, as well as the right shape and standard sizes. A good brick has a metallic, ringing sound when tapped. It breaks into large pieces instead of crumbling when hit with a hammer or chisel.

Underbaked brick should never be used for oven laying due to its extreme fragility, porous nature, poor resistance to frost, and rapid absorption of moisture. These bricks sound muffled when struck and have pale mustard colors. Overfired bricks melt and char, turning them black all the way through. We refer to these bricks as ironstone. It becomes extremely resilient to outside factors, making it ideal for foundations or sewers but inappropriate for a stove.

Be sure to examine the markings on bricks before purchasing. It is important to distinguish it from other brick varieties that are wholly inappropriate for use in masonry, such as acid-proof bricks, which resemble fireclay in terms of appearance and color.

The letter "SH" should be used on the label for fireclay bricks.

Bricks made of fireclay need to have the letter SH on them.

Fireclay bricks are used only for masonry and firebox linings in the great majority of cases. However, it is acceptable to build fireplaces and stoves out of firebrick exclusively, particularly when red brick’s architectural qualities aren’t up to par. Fireclay bricks are elegant, dependable, long-lasting, and simple to cover with ceramic or porcelain tiles. Furthermore, the masonry process is made much simpler by its excellent geometry. However, since fireproof brick is far more expensive than red brick, you should consider your financial situation.

After selecting a brick that works well, we can start preparing the mortar for it.

Preparation of raw materials

The easiest solution is to purchase brick-making clay from a building supply store. In this scenario, they will still be less expensive than pre-made items, and you will be certain of the type of material you are working with. Clay is also easily extracted by hand because it is nearly always found beneath the topsoil. A material devoid of pebbles, carbonate inclusions (white particles larger than 1 mm), and the fertile layer is what you need.

You can plan excavations on your own land, gather clay from the closest quarry or ravine, and request to gather the raw material from a nearby construction site that has a recently dug pit. In any case, the clay’s grade will need to be independently determined before using it to make bricks.

Clay is categorized into three types based on grade:

The following technique can be used to identify the type of clay you have:

1. From a small amount of raw materials (about half a liter) prepare a solution, adding water little by little and stirring constantly. The necessary consistency is considered to be achieved when the clay absorbs all the water and becomes sticky.
2. From the solution make two products: a cake the size of a small saucer and a ball about 4-5 cm in diameter.

Test samples are dried for two to three days at room temperature in an area shielded from draughts and direct sunlight. Following this, their condition is examined:

1. If the surface is covered with cracks, it means that this clay is greasy and sand should be added to it.
2. If there are no cracks, the clay workpiece in the form of a ball is dropped on a hard surface from a meter height. If it has not broken, the raw material is of normal fat content. It is the easiest way to make bricks from this type of clay. If the ball fell apart, it means that the raw material was caught skinny and before making bricks from it, you should dilute it with fat clay.

Five fresh mortar portions, each containing additives such as sand or fat clay added in varying amounts, are typically kneaded all at once. The mortar that performs the best is then determined by testing it one more time.

Clay’s plasticity is one of its key qualities. Plastic clay is the most practical material to work with.

There are two methods to impart this property to the raw material:

1. Freezing (available in winter).
2. Aging in a soaked state. Clay, stirring, pour water until completely soaked, after which the container is covered with polyethylene or a damp cloth and left for 3 or more days.

Sufficiently plastic material molds well, holds its shape, and doesn’t adhere to metal or human skin. Such a test can be performed by rolling out and winding a sausage the thickness of a finger around a bottle or dummy with a comparable diameter. High-quality mortar will not smear on the dummy and will not break while maintaining its integrity.

You can reinforce the mortar by adding up to 20% of sawdust, peat crumbs, or grain husks. If cracks still show up, these additions will help. Particle size limits are set at three to five millimeters.

Bricks can be made from clay mortar if all the requirements are met.

Mold for manufacturing

250 x 120 x 65 mm is a better size for the homemade mold to make standard. The mold’s bars need to be fastened together with nails.

When made from premium clay by hand and dried in accordance with all regulations, raw (unfired) brick is similar to its red (fired) counterpart. It works well for erecting modest residential structures like sheds and bathrooms. It makes sense to create it with your hands at home for these uses.

In the factory, a molding press is used in industrial production. However, it is inefficient to purchase a press because the owner who wishes to construct, say, a shed, does not have the responsibility of flow production.

The most basic mold is what you’ll need to start producing building materials. It can also be made by hand, without the need for any technical tricks, at home. The simplest supplies are needed: two plywood sheets and non-thick, 20–25 mm thick boards. It is best to create multiple molds in order to work more quickly. This design will take the place of our industrial press in terms of functionality, and the final product won’t be any worse.

The size of the mold can be varied at your discretion, but it is better to make the cells under the standard dimensions – 250x120x65 mm. On the top and bottom lid it is better to make small protrusions of conical shape. They are intended to form voids in the finished products, which will improve their contact with the mortar. All parts of the mold between each other are fastened with nails 50-60 mm, and the top cover is left unfastened to remove it when filling the mold and removing the molded brick from it. Perhaps, if you use a press, the bricks will be more even and uniform, but even in this form they turn out pretty good.

Although some artisans construct the press themselves, the above-discussed mold will do since we are now discussing the most basic production technique. However, since the press is a complex structure, it deserves its own article.

Final aging of the mortar in the molds

Since aging has a significant impact on the final product’s strength, all requirements must be met in this case as well.

While the workspace is being seasoned, it should be kept warm. Refractory concrete experiences hydraulic setting a few hours after pouring; this process is largely dependent on the water content and material quality.

The product stays extremely hot for several hours as a result of this reaction.

To stop water from evaporating from the surface of the molds during this process, it is crucial to carefully cover them. After cooling, the molds can be removed and used right away, but it is best to leave them in the molds for a few days to get the best results.

Keeping them moist for a few days after manufacturing is another wise choice.

How to prepare mortar for refractory bricks

It is important to keep in mind that red bricks should only be laid on red clay, and refractory bricks should only be laid on refractory clay.

A ready-made dry mix called fireclay mertel is used to make the mortar for fireclay bricklaying.

Can be made by hand or by using a pre-made dry mix, commonly known as fireclay mortar. In any case, clean, preferably oil-free, impurity-free rainwater with a low salt content should be used to prepare refractory mortar. We will require three buckets of mortar, or roughly forty kg of dry mixture, to make one hundred bricks. Thus, double-check your stove’s layout carefully before mixing or buying mortars.

Fireclay mortar, or ready-made dry refractory mixture, functions on the well-known "just add water" premise. The refractory mortar is mixed with water until it has the consistency of thick sour cream. It is combined in large quantities using an electric drill or mixer, preferably a concrete mixer (mix for at least 5 minutes). The mortar is mixed, then allowed to sit for an hour before being mixed once more. It is advised to add Portland cement in an amount equal to roughly 15% of the dry mix’s initial amount for strength. Now that everything is prepared, refractory bricks can be laid.

The masonry on the mertel exhibits significant shrinkage and is less durable than mortar mixed on refractory clay with the addition of fireclay sand, despite the fact that using a ready-made mixture saves time and effort. Therefore, mixing the mortar yourself is preferred.

For ten to twelve hours, fireclay is soaked and then stirred periodically.

To accomplish this, soak a pack of ground refractory clay, also known as white kaolin clay, for at least 12 hours, preferably for two to three days. Blue Cambrian will do if kaolin is absent. The clay should be fully submerged in the water. Stirring the soaked clay periodically is recommended. After that, the clay is carefully scoured through a 3 by 3 mm mesh sieve.

The scent of clay is something you must notice. It usually doesn’t smell

A strong, disagreeable smell suggests that there may still be organic additives present. Sand is added after the clay has been thoroughly soaked and massaged.

Adding quartz sand or granite or marble crumbs is not acceptable. The best application is fireclay sand, which is a tiny scrap of broken fireclay bricks. It is acceptable to use mountain sand in the absence of fireclay sand, free of silt and other unnecessary contaminants. The sand must first be filtered through a fine sieve. The ideal ratio is 1:2 between refractory clay and fireclay sand.

Nuances of making clayite

Glinobite is described as a dense, impurity-free mass composed of fat clay. The entire process of preparing it involves tamping down the clay thoroughly and diluting it with water. The mortar gets thicker as the water evaporates.

• The readiness is checked in the grandfatherly way: put on a stick clay bar, and if it is only slightly bent and no longer deformed – it means that the earthenware is of high quality. It is this sand that is used to make clay bricks (clay concrete stone).
• It is an excellent material for the construction of stoves, but for the construction of houses people have long preferred to make stones with a filler in the form of straw, wool, sawdust. The reason is simple: they make the walls warmer.
• In rural areas located in the southern latitudes, clay straw stone (adobe) is still quite popular today. It is used to build not only barns, chicken coops and pigsties, but also residential houses.

Double-decker adobe home

External wall cladding using alumina concrete

The fact that such a house can look extremely interesting and even have a claim to originality, along with the minimal price that will have to be paid, makes the owner doubly happy.

Features of clay stone

However, unlike adobe, clay concrete molded stone can only be dried or fired. It will be a raw brick in the first instance and a complete brick in the second.

The weight of a hand-formed clay brick ranges from 3.25 to 3.45 kg, and it is not much different from a standard full-body brick when standard dimensions are followed.

Hand molding light clay fired bricks

Even though the bar’s geometry occasionally deviates from the accepted norm and has a pleasing appearance overall, it can be applied to face masonry facades that are decorated in an antique manner in addition to stove construction.

Brick made of red clay

Regarding adobe, its improved thermal conductivity results from its porous nature after firing. Straw burns away during the firing process, causing pores to form.

In this instance, moisture can no longer affect the stone. In this instance, it can be applied to private building even in humid climates.

Masonry wall with a brick exterior

In addition to being warm, a house with face brick covering its adobe walls will look fairly respectable, as demonstrated in the example above. When compared to cellular concrete blocks, which are much more expensive and not always available, saman is an excellent substitute.

Kiln claying

When building stoves, bricklaying on clay is also preferred; this is no longer done for financial reasons. The brick and clay mortar combine to form a monolith that perfectly retains heat in high temperatures. For this reason, the top of kilns is frequently entirely covered in clay.

In order to get a quality clay-bite

The clay that is used for mixing needs to be homogenous in order to produce the proper clay mass. The clay cannot contain even a tiny bit of gravel. It merely disintegrates the stone from within when heated, expanding more forcefully.

• To get a good quality red clay brick, or mortar for laying the oven, it should not have lime inclusions as well.
• At high temperatures, lime turns into kipelka, and in case of contact with water, it provokes the formation of bloating and cracks in the bricks.
• Therefore, when filling the clay with water, it is first probed with hands, removing all large inclusions. If they are lumps of lime larger than 3 mm, it is necessary to determine their percentage content.
• To do this, weigh the entire portion of soaked clay, and separately – lime lumps. It turned out that for 5 kg of clay there is more than 0.5 kg of lime? It is definitely unsuitable for kiln bricks!

The feet are used to knead the clay.

• In general, the best helper in making clay is time. If you are serious about making your own bricks, keep in mind that the preparation of clay should begin a year in advance, or better yet, two years in advance.
• It is spread in the vegetable garden in a layer of 10-12 cm, and left directly under the open sky. Multiple cycles of freezing and thawing will destroy all the impurities, and only quality clay will remain.
• Its even saturation with water is an extremely important nuance. Therefore, before mixing the mortar, it is simply poured and allowed to swell for a few hours.

After being combined with a shovel and compacted with a tamper, the mass is only then ready to be mixed with the feet. The compacted clay is then covered with a damp cloth and allowed to lie for an additional 10 to 12 hours before the clay brick can be molded.

Raw material firing technology

Diagram of an industrial kiln’s brick-firing process.

The brick needs to be inserted into the barrel with tiny gaps to ensure optimal heating. If you don’t have an industrial furnace, you can accomplish this work with a regular barrel that holds 250 liters of material.

First things first, a 50 cm-deep pit needs to be prepared for the fire. Remove the bottom from the barrel and place it on legs that can only be 20 cm long to hold it over the fire. As a result, controlling and maintaining the fire will be more comfortable, and the clay brick will heat evenly.

Once the barrel has been filled with clay-based bricks, it needs to be covered with a steel sheet; at this point, the removed bottom can be used. This phase will require 18 to 20 hours, during which the fire must be maintained. The barrel’s lid shouldn’t be opened until it has had time to cool. The fire needs to be put out gradually. The completed items can be taken out five hours after the barrel and bricks have cooled.

The following tools are used to make bricks: 1 pusher, 2 planking, 3 sand with scoop, 4 shovel-wielding clay, 5 mortar, and 6 brace or scraper.

Products made of clay may have ingredients added and mixed in different proportions. Thus, to obtain adobe, you need to initially prepare an oversized container, which has low sides. Such a container is convenient for mixing the mixture. For mixing, it is necessary to use a combination of two types of clay, one of which is lean, the other is greasy. The composition should also include straw, the final proportion is as follows – 1:1:5. To the components mentioned above, you need to add water, and then mix with a shovel. If for bricks you decide to use the above recipe, then before starting work, the straw should be crushed. If you neglect this requirement, then the lumps will cause a decrease in the strength characteristics of the brick. It is preferable to use wheat stalks that have undergone quality drying.

If desired, dimensions other than the standard dimensions can be provided in the case of independent production of clay-based products.

Because the adobe clay that makes up bricks has a low water-resistant characteristic, the products need to be kept dry if they are going to be the foundation of external walls. For this reason, the roof overhangs must be at least 60 centimeters long, and the joints must be securely tied. The distance between openings and corners should not be less than 1.5 meters. The surface of the walls will need to be plastered as soon as the walls are folded and the house shrinks; alternatively, you can use siding and cladding for protection.

A plan for dividing bricks to check their quality.

In the event that you choose to work with bricks that don’t contain straw, you should substitute a small quantity of sand for straw in the mortar. The ratio stays constant. For this application, pure quartz sand with fine grains is ideal.

You must evaluate the brick’s quality, size, and accuracy of shape after it has been fired. A hammer should be used to crack one product in order to analyze its quality attributes. The product will remain the same color after a good firing, and this also holds true for the structure during the break. The brick test is not over yet. Water must still be poured over the brick and allowed to sit for a while. The color and structure will be consistent across the whole surface if the material is properly fired.

Because of this, ceramic bricks can be produced on their own without the need for a press or other sophisticated industrial machinery.

Returning to the contents table

Technology of manufacturing fireproof brick components and the process of creating the material

Characteristics of the fix.

The goal of a fireclay brick stove is to provide a complete heating system for the room, and it is a model of construction efficiency and dependability. By using such a material, an excellent system with maximum strength and ideal properties can be achieved. One of the best materials on the market right now is fireclay brick. The composition and manufacturing process of this material, which enable exceptional fire resistance and strength properties, are first and foremost responsible for its key attributes.

White kaolin refractory clay is the primary ingredient in the refractory material. Because of its extreme malleability and plasticity, it is completely unsuitable for shaping and producing hard products. As a result, it is fired first, and then the mass hardens and is kneaded until it becomes powdery. This produces refractory clay, which possesses all the required strength and dependability. There are three primary components to fireclay kiln bricks:

Mortar types and proportions.

The process of baking, which is one of the product’s production methods, also contributes to the acquisition of its fundamental characteristics. Up to 1000 degrees Celsius are reached during the firing process of the formed products. This results in the material’s base becoming harder and its porosity being reduced to almost nothing. Such a material is easy to identify because it is made of chamotte, which gives it a granular structure, yellow color, and a weight of up to three kilograms.

Possible consequences

While some mistakes are understandable, disregarding the need for specialized heat-resistant mortar can have disastrous results. A severe crack or total looseness of the interbrick connector can result from improper mixing. Then, you will witness the entire thing buckling and collapsing in front of your eyes.

Many homeowners who had grills, braziers, pipes, stoves, and other appliances made by careless, repulsive artisans sought assistance. However, we were only able to fully disassemble and reassemble the entire structure.

The look on the face of a man who realized the meat would have to be grilled over a regular fire after marinating it was excruciatingly painful. Right then, things took a turn for the worse when he turned to look, and a section of the chimney fell inside the made-in fireplace. The fact that Santa Claus wasn’t the one who broke it made it all the more annoying.

Sure, here"s a paragraph for your article:"In the realm of creating durable bricks for building homes, understanding the composition of clay is crucial. Clay, the primary material for bricks, consists mainly of fine-grained minerals and organic matter. Its composition varies depending on factors like geographical location and extraction methods. Typically, clay contains silica, alumina, and various metal oxides, which give bricks their strength and durability. The balance of these components influences the brick"s color, texture, and performance. Moreover, additives like sand and shale may be included to enhance the clay"s properties. By comprehending the composition of clay, builders can produce high-quality bricks that excel in insulation, structural integrity, and overall longevity."

Analyzing the quality of clay

A system for evaluating clay quality.

You must determine how oily the clay is before adding it. You can accomplish this in one of the following methods. The most straightforward method of verification involves using 0.5 liters of clay and adding water while stirring. Continue until all of the liquid has been absorbed by the clay and it no longer sticks to the hands’ palms. Once the solution is ready, a small ball with a diameter of about 5 cm should be formed out of it. A flatbread measuring 10 cm should also be prepared. After three days, the figures should be left in the shade.

Then you can check to see how strong they are, if there are any cracks in the surface. When confirming the latter, sand should be added to the clay, as it is excessively oily. If there are no cracks, the figure should be thrown, raising it to 1 m. The ball will not be damaged if the clay is of optimal fatness. If it is excessively lean, then on the surface of the figure from it will not form cracks, but also the strength will not be high. In order to obtain a suitable fat content of clay, sand should be mixed in gradually. As soon as the clay acquires the desired characteristics, it can be used for the production process.

Returning to the contents table

Roasting with your own hands

It’s essential to lay the bricks in the barrel with tiny spaces between them for uniform heating.

The only option left is to attempt firing in a regular barrel with a capacity of 200–250 liters, as not everyone has access to an industrial furnace for this purpose.

A pit that is 40–50 cm deep is required for a fire pit. The bottom of the barrel is removed, and it is set atop 20 cm-tall legs over the fire. As a result, controlling and maintaining the fire will be easier, and the brick mass will heat evenly.

Bricks should now be placed inside the barrel. One must be placed on top of the other, with tiny spaces between them. The barrel must then be covered with a metal sheet to keep cold air out while it is being fired. Here, a cut bottom can be helpful; it will be even more practical if handles are attached.

You now need to refuel with patience and gasoline. During the 18 to 20 hours that the process takes, it is important to make sure there is always fire under the barrel while the bricks are being fired.

The barrel should then begin to cool. The lid must not be opened; instead, this should be done gradually. To lessen the fire, the temperature should be gradually adjusted. This is not the place for artificial cooling—only natural cooling will do.

You can remove the completed burnt products by opening the lid and waiting four to five hours after the barrel and its contents have cooled completely.

A quick test should be conducted to ensure that the work is completed to a high standard.

For this to work, one brick must be broken with a construction hammer. It will remain the same color and texture during the break if it is fired properly. For a few hours, these debris should now be submerged in water. A well-fired brick ought to be uniform in both color and texture throughout after being submerged in water.

When everything is finished and of high quality, the process of firing yourself is complete. It follows that it is quite feasible to create artificial stone on your own without the need for a press or other industrial machinery.

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Fresh records

One of the essential materials that is frequently used in home construction or renovation is clay. For centuries, clay has been used in construction, especially to make bricks. However, what precisely is in the clay used to make bricks? Comprehending this vital element can significantly influence the resilience, insulating properties, and general caliber of the bricks employed in your residence.

In its most basic form, clay is a kind of soil that is high in water, alumina, and silica minerals. Clay’s special qualities—which include being pliable when wet and robust when dry—come from these minerals. But not all clay is made equally. The geological history, location, and presence of other materials can all affect the composition of clay.

The final characteristics of bricks are largely determined by the composition of the clay used in their production. Different mineral ratios in the clay mixture can have an impact on the bricks’ strength, color, porosity, and thermal conductivity. For example, bricks with higher silica content may be stronger, and bricks with higher alumina content may be better able to withstand heat.

In addition, the composition of the clay must be carefully considered before it is ready to be used to make bricks. To achieve uniformity and eliminate any impurities, clay must be refined, typically through a procedure known as pugging, which involves mixing, kneading, and de-airing the material. After being refined, the clay is formed into bricks and heated to high temperatures in kilns to solidify their structure.

Comprehending the composition of clay used to make bricks is crucial not only for architects and builders but also for homeowners who want to make sure their homes are long-lasting and energy-efficient. Understanding the components of bricks used in building allows one to make choices that improve a home’s overall comfort and sustainability.

Component	Percentage
Clay	60-80%
Sand	20-40%

Chamotte production

GOST 390-69 specifies the production process for alumina bricks. Two sizes are available for production: 250*123*65 mm and 230*113*65 mm. It is distinguished by a structure with fine grains.

Blocks are composed of 70% fireclay, 30% coke, and powdered graphite. The block comes in weights ranging from 2.5 to 6 kg, depending on its size and structure.

Withstands temperatures between 1000 and 1800 °C. When the temperature is repeatedly changed sharply, it does not react at all. Professionals utilize this kind of building material to construct home fireboxes.

Characteristics that set refractory blocks apart:

1. When tapped, refractory bricks produce a ringing metallic sound.
2. Moisture resistant.
3. Sandy yellow color with a granular base.

Manufacturers produce a range of refractory bricks. They vary in porosity, manufacturing process, mass, size, and shape. There are the following varieties available:

• straight;
• trapezoidal;
• arched;
• wedge-shaped.

These chamotte varieties enable the building of any kind of structure.

The composition and level of porosity are taken into consideration when making fireclay bricks.

Refractory material comparison.

1. Extra dense. Its porosity is less than 3%.
2. High-density. Porosity – from 3 to 10%.
3. Dense. Porosity – up to 16%.
4. Compacted. The porosity is up to 20%

These characteristics of refractory bricks aid in selecting building blocks with skill.

Fireclay bricks are classified into the following categories based on the formation method:

1. Cast from slag.
2. Fused.
3. Molded by semi-dry or plastic method.
4. Hot-pressed.
5. Thermoplastic.

Molding and drying

Clay that has been prepared ahead of time is applied to the ground in layers as thick as 40 cm. When combining various clay types with varying plasticities or adding additives (sand, slag, sawdust), it is preferable to use containers (wheelbarrows, stretchers, or buckets) to ensure strict adherence to component proportionality and total homogeneity of the mass rather than estimating dosage by eye.

Bricks are typically molded by plastic pressing or by placing the dough in molds. A doughy mixture is used for brick molding.

This dough needs to be in a condition that allows the formwork to remain in place. Only when the dough’s moisture content is between 18 and 20 percent is this feasible. This type of dough molds easily and uniformly, but it takes a long time for natural drying to occur (usually with no other option).

Depending on the environment and location, it can take anywhere from one week to one month to dry raw bricks to a final moisture content of 6-8% (raw bricks dry faster and better in a draught under a roof than in other conditions).)

The following indicators indicate if raw bricks are ready for firing: if bricks from the middle rows break in half and there isn’t a dark spot in the center, which indicates moisture, the raw brick is considered ready for firing.

The press mentioned above presses the initial mixture with a natural moisture content of 6-8%, or a mixture of 6-8% freshly excavated clay with the dry layer removed. Semi-dry pressing, sometimes known as dry pressing in some literature, is the method used.

After thoroughly crushing the clay, it is combined with additives and placed in the press’s hopper for molding. In a preparation like this, the clay already contains enough water; additional water is not needed.

After a day of drying in warm weather, a product of this kind is ready for firing. The raw bricks need to be dried if the raw material is excessively moist.

The raw material should be dried in stacks if the humidity is still high enough after pre-drying. Bricks are placed in two rows on the edge, spaced 2-3 to 5-7 cm apart. The stack’s width is 60 cm at the top and 80 cm at the base.

To prevent the brick from deforming, place more dried raw material in the lower rows than necessary to support the weight of ten rows in the upper rows.

To minimize defects or deformation during brick laying, a horizontal platform is set up. In order to shield the bricks from sediment water runoff, this area needs to be above ground.

To shield the stacks from the sun and rain after the bricks are laid, they are covered with plastic or tol. Bricks that are exposed to direct sunlight dry unevenly, which leads to the formation of cracks.

Bricks must be laid end to end in the direction of the prevailing winds to minimize the chance of cracks forming during the drying process.

Brick firing process during production

If the production process using raw materials is insufficient, you can attempt making firing at home. This technology requires a lot of labor and is highly complex. Making a lot of bricks at home in this manner is not logical. It is feasible to produce a small batch, however, as little as 50 pieces.

There are three steps: heating, firing, and cooling, just like in ceramics.

• During the heating stage, both hygroscopic and hydrate liquid evaporates from the product. In this case, all organics are burned and carbonates decompose. A general heating of the whole brick is also carried out.
• Further, at the stage of firing, the clay changes its chemical state, which as a result and forms a solid structure of the product. The temperatures at which these processes are carried out are within 1200 degrees Celsius.
• However, simple firing is not enough to form a durable product. Continue the process by cooling the brick. It is necessary to gradually reduce the temperature, bringing it to 600 degrees, after which you can slightly accelerate the work. Abrupt changes in temperature will cause defects – cracks on the bricks.

Under production conditions, a similar process is carried out in dedicated ovens. This procedure is set up in a metal barrel at home. The container’s bottom must be removed before lighting it on fire. First, you need to dig a pit for the fire that is about 5 cm deep. You can manage and sustain the fire by supporting the barrel with bricks or metal legs.

• Raw bricks are placed in the structure – one on top of the other. It is also necessary to leave gaps for air flow.
• Next, the barrel should be closed from above, using the bottom cut out earlier for this purpose. This is necessary to prevent the passage of cold air from the outside.
• The firing procedure lasts about 20 hours. During this time, a steady fire must be maintained. The strength of burning is determined experimentally. After completing this time, it is necessary to begin to reduce the strength of combustion. Keep the lid closed for at least another 5 hours. After that you can check the result.

The product should be tested by breaking it with a hammer once it has fully cooled. A homogeneous structure that is uniformly colored should be visible on the fracture. The broken brick should then be submerged in water for a while.

A high-quality product ought not to crack or lose its color. If you’d like, you can check the strength of the home brick by comparing it to the factory analog. It makes sense to consider home production in larger quantities if the final product is not worse than what is produced in a factory.

Making raw bricks at home is a real task, but you will need to put in a lot of effort to get a fired brick.

Respecting the temperature range and the amount of time needed to wait for the outcome is crucial. Rushing through the cooling process can taint the outcome of your diligent labor.

Safety precautions should be taken when handling such difficult tasks at home. Only perform your work in an area free from fire hazards. Avoiding the presence of combustible compositions nearby is essential for the same reason.

Basically, just take a risk and everything will turn out beautifully in the end!

Properties, composition of raw materials

The following ceramic materials are used in the manufacturing of ceramic bricks and ceramic stones:

Fusible clays, also known as trepel and diatomite rocks, are clayey rocks that occur in nature in a dense, friable, and plastic state.

Mineral and organic additives (such as quartz sand, slag, fireclay, sawdust, coal, ash, and others) that improve the characteristics of natural raw materials.

Refractory bricks for creating textured face bricks made of light-fusing clays, glass, chalk, waste from the production of porcelain, and light-fusing refractory and refractory clays.

The primary raw materials used to make bricks are easily fusible clays, which are earthy rocks that, when combined with water, can form a plastic dough that, when fired at 800-1000 0 C, solidifies into a substance resembling stone.

Rocks that are sedimentary and residual contain fusible clays. Bricks are mostly made from alluvial, humid, glacial-marine, marine, and a few other clays and loams.

Understanding clays and loams’ grain, chemical and mineralogical composition, plasticity, and technological qualities is essential to determining whether they can be used to produce wall materials.

The clay fraction, which should contain at least 20%, is the most valuable for making bricks.

An essential factor in characterizing clay is its alumina Al2 O3 content. growing raw material technological properties: in fusible clays, it can be anywhere between 10 and 15 percent

SiO2 has a silica content of 60–75%. A portion of silica occurs in clay-forming minerals in bound form and as an impurity in unbound form that has the characteristics of calcareous materials in clays.

Calcium is found in clays in the form of carbonates and sulfates, and magnesium in the form of dolomite. In some clay varieties, the presence of calcium and magnesium in terms of their oxides (CaO and MgO) reaches 25%, but, as a rule, their total content does not exceed 5-10%. Usually calcium and magnesium compounds have a negative effect on the sinterability and strength of ceramic products. If clay rocks contain more than 20% carbonate impurities, they cannot be used without appropriate treatment or beneficiation. Oxides of iron, titanium, manganese and other metals are found in clays in amounts up to 10-12% and have a significant influence on a number of important properties of ceramic products. The greatest influence is exerted by iron oxides in clay in the form of Fe oxide₂ O₃ and Fe(OH) hydroxide₃ and manganese oxides MnO_2. They improve the sinterability of the products and give them coloration.

3.5–5% of clays contain alkaline oxides, which are the form in which potassium and sodium are found.

Although sulfur can be found in clays in a variety of forms, the quality of ceramic wall products is unaffected by its presence.

Clays typically contain five to ten percent organic matter. The products burn out during firing, which makes the tile more porous. The index of loss on ignition depends on the amount of organic matter, water, and carbonates (CaCO3. MgCO3) in the clay (tab. 1).

Estimated chemical composition in percentage terms of brick clays and loams.

Selecting the proper clay composition for bricks is essential to the longevity and effectiveness of the insulation and heating system in your house. For centuries, clay bricks have been a mainstay in construction because of their exceptional thermal qualities and natural abundance. The mineral content and moisture content of clay have a direct effect on the bricks’ performance and quality.

Prioritizing certain qualities is crucial when thinking about the clay composition for bricks. The strength and insulating qualities of the bricks can be improved with a well-balanced mixture of clay, sand, and additional ingredients like fly ash or shale. In order to form easily into bricks, the clay needs to have a certain amount of plasticity, and adding sand helps to minimize shrinkage during the drying and firing processes.

Furthermore, a major factor in determining the ultimate quality of the bricks is the firing temperature. Bricks fired at higher temperatures have a higher density and are more durable; bricks fired at lower temperatures may be softer and have a lower thermal resistance. The ideal firing temperature is determined by a number of variables, such as the kind of clay, the desired characteristics of the brick, and the resources that are available.

In conclusion, a key component of creating an energy-efficient and well-insulated home is the clay used to make bricks. Homeowners and builders can guarantee the longevity and efficiency of their heating and insulation systems by making educated decisions based on their understanding of the characteristics of various clay materials and how they interact during the manufacturing process. Bricks can offer exceptional thermal performance with the correct clay composition, resulting in a more comfortable living space and lower energy costs for many years to come.

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