By-APOORVA

SHAGUN

CLAY
SOMYA AGARWAL
YASHASVI DARBARI
MUSKAN SINGH
KANCHAN
BUILDING CONSTRUCTION AND MATRIAL VIRAT SINGH
 Clay is a natural material which form
over millions of year and can be
found in gardens , riverbeds , field or
even along roadsides.
INTRODUC Clay form mostly in areas containing
large amount of granite.
TION OF
CLAY
Clay is composed of alumina , silica
and granite as well as other smaller
amount of minerals.
HISTORY OF CLAY
Clay is a type of fine-grained natural soil material containing clay minerals. (hydrous
aluminium phyllosilicates, e.g. kaolinite, Al2Si2O5(OH)4
Clay is the oldest known ceramic material. Prehistoric humans discovered the useful
properties of clay and used it for making pottery. Some of the earliest pottery shards
have been dated to around 14,000 BC.
Clay is used in many modern industrial processes, such as paper making, cement
production, and chemical filtering. Between one-half and two-thirds of the world's
population live or work in buildings made with clay, often baked into brick, as an
essential part of its load-bearing structure.
FORMING OF CLAY
It is formed by two processes:
1.EROSION:
This involves washing and wearing of rocks by agents of erosion like water wind
and others to form different soils of which clay is part.
These rocks may include sedimentary rocks.
2. WEATHERING:
This process involve physical and chemical disintegration of rocks containing clay
minerals forming clay deposits
 Clay is basically classified according to the following
1. Based on the mode of formation

Residual clays, known as Kaolin or China clay, are

CLASSIFIC formed from the decay of underlying rocks and are used
for making pottery.
ATION:
Transported or sedimentary clays result from the action
of weathering agencies. These are more disperse, contain
impurities, and free from large particles of mother rocks.
CLASSIFICATION…
2. Based on dominant characteristics

China clay: This is the purest kind of clay containing a very high percentage of
kaolin and is used in making porcelain , fire resisting cement and white Portland
cement.

Fire refractory clays: These contain silica and alumina in very high proportions and
are capable of withstanding very high temperatures without deforming in shapes.
 Modelling clay is used in arts and handicrafts for
sculpting.
Clays are used for making pottery ( both utilitarian and
decorative).
USES OF Different types of clay, when used with different
CLAY minerals and firing conditions, are used to produce:
1. Earthenware
2. Stoneware and
3. porcelain
 CLAY USE IN
CONSTRUCTION
As a building material, it is used in the form of brick
either sundried or fired.
Clays are also of great industrial importance .
Eg- . in the manufacture of tile for wall and floor
coverings, of
porcelain, china, and earthenware and of pipe for
drainage and sewage.
 Clay product which are
employed in building
industries are:
1. Tiles
2. Terra-cotta
3. Earthenware
4. Stonewares
5. Porcelain
6. Bricks

CLAY PRODUCT
 Tiles are used for various purposes in
building industries.
They are thinner than bricks , and
hence carefully handle to avoid any
damages to them.
CHARACTERSTICS OF GOOD
TILES:
It should be free from any cracks ,
flaws, or bends.
It should be regular shape and size.
It should be sound hard and durable.
It should be well burnt
It should possess uniform colour.

TILES
 Terra means “earth” and cotta means
“baked”. Hence, terracotta means baked earth.

It is type of earthenware.

TERRA- VARITIES OF TERRA-COTTA:

COTTA
Porous terra cotta

Polished terra cotta

 To prepare porous terra-cotta saw dust or ground cork is
(A) added in clay before the stage of moulding when articles
from such clay are burnt in kiln organic particles are
POROUS burnt and they leave pores In the articles.
Porous terracotta is a fire proof and sound proof
TERRACOT material.

TA It can be sawn and nailed easily with nails, screws etc.

It is light in weight and it is structurally weak
(B) POLISHED
TERRA COTTA
This is also known as fine terra-cotta or faience.
To obtain this variety of terra cotta articles are burnt at a
lower temperature of 650°C.
First burning is known as buiscuitng
Articles brought to biscuit stage are remove are removed
from kiln and are allowed to cool down.
They are then coated with glazing compound and burnt
again in the kiln at a temperature of about 1200°C.
Faience is available in a variety of colours and it
indicates super quality of terra cotta.
EARTHENWARE
The term earthenware used to indicate wares or articles prepared
from clay which is burnt at low temperature and cool down slowly.
Clay is mixed with required quantity of sand, crushed pottery etc.
Addition of such materials prevent shrinkage during drying and
burning.
Earthenwares are generally soft and porous.
When glazed earthenwares become impervious to water and they
are not affected by the acids or atmospheric agencies.
Terra cotta is a kind of earthenware.
STONEWARE
The term stoneware is used to indicate wares or
articles prepared from refractory clay which is
mixed with stones and crushed pottery.
Such a mixture is then burnt at a high temperature
and cooled down slowly.
Stoneware is more compact and dense then
earthenware.
When glazed stoneware become impervious to
water and they are not affected by the acids or
atmospheric agencies.
PORCELAIN
It is used to indicate the fine earthenware which is white,thin and semi
transparent .since the colour of porcelain is white .it is also referred to as whiteware.
Clay of sufficient property and processing high degree of tenacity and plasticity is
used in preparing porcelain.
It is hard,brittle and non-porous.
It is made from felspar, clay , quartz and minerals.
The constituents are finely ground and mixed in liquid state.
The mixture is given the desired shape and it is burnt at high temperatures.
CLAY BLOCKS
Blocks can be prepared from clay and they are used in the
construction of partitions.
Such blocks may be either solid or hollow .
Blocks are usually of section 30cm x 20cm.
Thickness of hollow block varies from 50mm to 15 cm .
Thickness in case of solid blocks is about 40mm
Blocks are provided with grooves on top. Bottom and sides.
These grooves help in making the joints rigid and they serve as a
key to plaster .
Sometimes, the surfaces of blocks are made glazed in a variety of
colours.
  Shibam skyscraper
 Yeman City
 Manhattan of the Desert for its
Multistory
 Taos pueblo in Mexico
 Game of Thrones filmed in
Morocco
 Ait Benhaddou is a fortified city
 Jemaa el-fnaa
 Moroccan Pavilion Putrajaya

MOST POPULAR CLAY  Puerta Baja

CITIES
  Yeman city
 Shibam skyscraper

 Manhattan of Desert for its Multistory  Taos Pueblo

  Game of Thrones filmed in Morocco  Ait Benhaddou is a fortified city

 Jemaa el-FnaaV  Moroccan Pavilion Putrajaya

PUERTA BAJA

The tall cluster of sun-dried mud brick tower houses *The mud-
brick high-rises, which stretch up to seven stories high, were
constructed from the fertile soil surrounding the city.* A soil, hay,
and water mixture was fashioned into bricks and left to bake in the
sun for days. *The windowless, ground floors were used for
livestock and grain storage, while the uppermost levels typically
served as communal floors for socializing. Construction-: adobe—
earth mixed with water and straw then either poured into forms or
made into sun-dried brick

 Harappa, Mohenjo-daro, Dholavira and

Rakhigarhi
CLAY
DECORAT
IVE
MATERIA
L
CLAY CLASSIFICATION
• On the Basis of their dominant Characteristics,
Clays are classified as intofour groups:
• China Clay
• Fire Clay
• Vitrifying Clay
• And Brick Clay
CHINA CLAY
• It is the purest type of clay containing very high
percentage of mineral Kaolinite or Kaolin
A*l_{2}*S*i_{2}*O_{5} (OH) 4 .
It is Considered high Grade clay and is used for the
manufacturing of crockery and other proclain ware.
FIRE CLAY
• They are also called refractory clay and contain, besides Kaolinite, Silica and
alumina in very high temperature without suffering any deformation off shape given
to them at the time of moulding.
They are mainly used in manufacturing of refractory bricks that are of great
importance in many metallurgical, mechanical and chemical operations
VERTIFIED CLAY
These clays are rich in fluxing compounds like iron oxide and carbonates of calcium
and magnesium.
These are easily fusible. i.e. cannot withstand high temperatures above 1100 ° C the
fluxes get softened and form glass like material that acts as a strong bonding agent
between the other clay particles.
This results in the formation of a smooth surfaced hard burnt clay products..
The Vitrifying clays called hard burnt clay are specially used for manufacturing of
facing brick, flooring tiles, sewer pipe and other similar ornamental and dense clay
products.
BRICK CLAY
These are low grade clays used most for the manufacturing of building bricks and
similar clay products.
Brick clay are rich in silica, alumina, oxide of iron, calcium, magnesium and organic
matter. It is mutual proportion of these components that define their suitability or
otherwise for making good quality bricks for building construction..
The oxides of iron, calcium and magnesium act as fluxes that fuse easily at brick-
making temperature and bind the alumina and silica particles thoroughly giving the
brick desired properties of cohesion and strength.
BRICK
• It is now established that even in remote ancient civilizations bricks were common
material of construction.
It is believed that it was in Egypt that bricks were used some 6000 years ago.
Excavation in prehistoric sites in our country has revealed that bricks were used
abundantly in Indus valley civilization at Mohan jo daro and Harappa.
AVALABILITY OF CLAY
Clay suitable for making bricks are available almost universally. Hence brick making
can be adopted anywhere in the world. This is not true either for stones or for
concrete that are material which compete with clay.
SIZE, SHAPE AND HANDLING
Bricks are made in ready-to-use sizes and shapes.
This affords very convenient handling and use.
For stones, however, some dressing is absolutely essential. In case of concrete, an
elaborate formwork and shuttering are basic requirements.
Moreover transporting and lying of concrete also and lying of concrete also requires
great care, caution and expertise.
SIZE-
TRADITIONAL-23cm x 11.4cm x 7.6cm
MODULAR -19cm x 9cm x 9cm
COST
• Bricks as also brickwork are cheaper compared to stone masonry and construction
with concrete in most cases.
This is because of the factors mentioned under availability.
Size and shape and construction methods
 CLAY TO BRICK
The fundamentals of brick manufacturing have not changed over time.


However, technological advancements have made contemporary brick plants substantially more

efficient and have improved the overall quality of the products.
A more complete knowledge of raw materials and their properties, better control of firing, improved
kiln designs and more advanced mechanization have all contributed to advancing the brick industry.

Other Technical Notes in this series address the classification and selection of brick considering the

use, exposure and required durability of the finished brickwork.
 ITS APPLICATION
 There are three ways to form the shape and size of a brick:

1. extruded (stiff mud),

2. molded (soft mud) and

3. dry-pressed.

The majority of brick are made by the extrusion method.

 Brick achieves its color through the minerals in the fired clay or through coatings that are applied before or after the
firing process.

 This provides a durable color that never fades or diminishes.

Brick will vary in size due to the manufacturing process.

These variations are addressed by ASTM standards.

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

Sand-finished surfaces are typical with molded brick.

A variety of textures can be achieved with extruded brick.

Brick manufacturers address sustainability by locating manufacturing facilities near clay

sources to reduce transportation, by recycling of process waste, by reclaiming land where
mining has occurred, and by taking measures to reduce plant emissions.
MANUFACTURING
There are four different operations are involved in the process of manufacturing of bricks:

1. Preparation of clay

2. Molding

3. Drying

4. Burning
A-PREPARATION OF CLAY
1.Unsoiling
2.Digging
3.Cleaning
4.Weathering
5.Blending
6.Tempering
The preparation of clay involves following operations
• Unsoiling: Top layer of 20cm depth is removed as it contain impurities.
•Digging: Clay dug out from ground is spread on level ground about 60cm to 120cm
heaps.
•• Cleaning: Stones, pebbles, vegetable matter etc removed and converted into
powder form.
•• Weathering: Clay is exposed to atmosphere from few weeks to full season.
• Blending:
Clay is made loose and any ingredient to be added to it is spread out at top and
turning it up and down in vertical direction.

• Tempering:
Clay is brought to a proper degree of hardness, then water is added to clay and whole
mass is kneaded or pressed under the feet of men or cattle for large scale, tempering
is usually done in pug mill as shown in the figure
PUG MILL

Process of Operation:

. Clay with water is placed in pug mill from the

top When the vertical staff is rotated by using
electric pair, steam or diesel or turned by pair of
bullocks

• Clay is thoroughly mixed up by the actions of

horizontal arms and knives.

• when clay has been sufficiently pugged, hole

at the bottom of tub, is opened cut and the
pugged earth is taken out from ramp for the
next operation of moulding.
CONTINOUS KILN
•The examples of continuous kiln are Hoffman's kiln and Bull's trench kiln.
•In a continuous kiln, bricks are stacked in various chambers where in the bricks
undergo different treatments at the same time.
•When the bricks in one of the chambers is fired, the bricks in the next set of
chambers are dried and preheated while bricks in the other set of chambers are loaded
and in the last are cooled.
GROUND MOULDED BRICKS
Ground is first made level and fine sand is sprinkled over it..
Mould is dipped in water and placed over the ground to fill the clay .
Extra clay is removed by wooden or metal strike after the mould is filled forced
mould is then lifted up and raw brick is left on the ground.
Ground moulded bricks of better quality and with frogs on their surface aremade by
using a pair of pallet boards and a wooden block.
Table Moulded Bricks:Process of moulding these bricks is just similar to ground
bricks on a table of size about 2m x 1m
MACHINE MOULDING:.
This method proves to be economical when bricks in huge quantity are to be
manufactured at the same spot.
It is also helpful for moulding hard and string clay.
These machines are broadly classified in two categories .
(a) Plastic clay machines
(b) Dry clay machinesa) Plastic clay machines:.
This machine containing rectangular opening of size equal to length and width of a brick.
Pugged clay is placed in the machine and as it comes out through the opening.
It is cut into strips by wires fixed in frames, so these bricks are called wire cut bricks.
DRYING
• The damp bricks, if burnt, are likely to be cracked and distorted.
• Moulded bricks are dried before they are taken for the next operation of burning.
• Bricks are laid along and across the stock in alternate layers.
• The drying of brick is by the following means
i. Artificial drying
ii. Circulation of air
iii. Drying yard
iv. Period for drying
v. Screens
BURNING
•This is very important operation in the manufacturing of bricks toimpart hardness,
strength and makes them dense and durable.
•Burning of bricks is done either in clamps or in kilns.
•Clamps are temporary structures and they are adopted to manufacture bricks on
small scale.
•Kilns are permanent structures and they are adopted to manufacturebricks on a large
scale.
KILN BURNING
•The kiln used for burning bricks may be Underground, e.g. Bull's trench kiln or Over
ground, e.g. Hoffman's kiln.
•These may be rectangular, circular or oval in shape.
When the process of burning bricks is continuous, the kiln is known as continuous
kiln, e.g. Bull's trench and Hoffman's kilns.
•On the other hand if the process of burning bricks is discontinuous, the kiln is known
as intermittent kiln
INTERMITTENT KILN
• The example of this type of an over ground , rectangular kiln is shown in Fig.
• After loading the kiln, it is fired, cooled and unloaded and then the next loading is
done.
• Since the walls and sides get cooled during reloading and are to be heated again
during next firing, there is wastage of fuel.
CONTINUOUS KILN
•The examples of continuous kiln are Hoffman's kiln and Bull's trench kiln.
•In a continuous kiln, bricks are stacked in various chambers where in the bricks
undergo different treatments at the same time.
•When the bricks in one of the chambers is fired, the bricks in the next set of
chambers are dried and preheated while bricks in the other set of chambers are
loaded and in the last are cooled.
HAFFMAN’S KILN
•This kiln is constructed over ground and hence, it is sometimes known as
flame kiln

Its shape is circular to plan and it is divided into a number of compartments

or chambers.

•A permanent roof is provided; the kiln can even function during rainy
season.

•Figure shows plan and section of Hoffman's kiln with 12 chambers.

Chamber 1 – loading

Chamber 2 to 5 - drying and pre-heating

Chambers 6 and 7 – burning

Chambers 8 to 11 – cooling

Chamber 12 - i unloading
BRICK MAKING
PROCESS
THANKYOU