Manufacturer ingredients process types uses

1. FIRE BRICKS & SAND
BRICKS
By :-
1. Ishpreet Singh Kapoor (CO18228)
2. Aman Sihag (CO1827)
3. Chetan Sharma (CO18219)
4. Aditya Singh Patyal (CO1825)
5. Ankush Dhaiya (CO18211)
6. Shivam Sharma (CO18250)

2. Topics
What Are these ?
Ingredients
Manufacturing Process
Types/ Varieties
Uses
Masonry/ How to Use

3. WHAT ARE THESE
?
Ishpreet Singh Kapoor

4. FIRE BRICKS
• A refractory brick is built primarily to withstand high temperature,
but will also usually have a low thermal conductivity for greater
energy efficiency.
• Usually dense firebricks are used in applications with extreme
mechanical, chemical, or thermal stresses, such as the inside of a
kiln or a furnace.
• In the making of firebrick, fireclay is fired in the kiln until it is partly
vitrified, and for special purposes may also be glazed.

5. • In other, less harsh situations, such as in an electric
or natural gas fired kilns, more porous bricks, commonly
known as "kiln bricks" are a better choice.
• The silica firebricks that line steel-making furnaces are used
at temperatures up to 1648°C (3000°F), which would melt
many other types of ceramic.
• Fire bricks may be called by various definitions. It depends
on who works with them, names them too.
• fire brick = fire-clay brick = refractory brick = chamotte brick
= fireplace brick = heat resistant brick = chimney brick =
dense/heavy kiln brick (for building kilns) = industrial ceramic
brick (heavy)

6. PROPERTIES of Fire Bricks
• Colour :- Whitish Yellow Or Light Brown
• Bulk Density : 1915 Kg/m³
• Modulus of Rupture : 5 MPa
• Permanent Linear Change on reheating 5 hrs. @ 1400°C : -
0.35%
• Cold Compressive Strength : 3.5N/mm2 to 48.26 N/mm2
• Thermal Conductivity @ 750°C : 1.01 W/m.°K
• Apparent Porosity : 28%
• Water Absorption :- 4% - 10%

7. SAND LIME BRICKS
• Sand-lime brick also known as Calcium Silicate Bricks is a
product that uses lime instead of cement. It is usually a
whitebrick made of lime and selected sands, cast in molds
and cured.
• The process for making brick of sand was discovered and
patented by Dr. William Michaelis in 1880.
• It has about the same hardness and porosity as common
clay building brick.

8. • Good acoustic insulation, good heat & humidity
accumulation as well as excellent fire resistance are the
main parameters for architects to prescribe lime sand
bricks for each building project.
• The strength of the brick must be considered as
dependent upon only that proportion of lime which has
been converted to the silicate rather than upon the total
lime added.

9. DIMENSIONS
of Fire Bricks
• 9×4½×3 inches (229×114×76
mm)
• 9×4½×2½ inches (229×114×64
mm)
• 9×4½×1¼ inches (229×114×32
mm) (Splits)

10. DIMENSIONS of
Sand Lime
Bricks
•190 mm x 90 mm x 90 mm
•With mortar, the dimension of the
brick becomes 200 mm x 100 mm x
100 mm

11. COMMON Defects in Bricks
•Over burning of bricks
•Under burning of bricks
•Efflorescence
•Brick cracking
•Brick spalling
•Lime blowing
•Lamination bricks
•Defects in brick size
•Defects in brick shape

12. INGREDIENTS
Shivam Sharma

13. FIRE BRICKS
• The chemical composition of a firebrick includes 23
percent alumina and 73 percent silica. Ferric oxide,
titanium and other metallic oxides form the remaining
portion.
• The major chemical composition of regular brick is
1. Silica,
2. alumina,
3. magnesia,
4. lime,
5. iron oxide,
6. alkalies.

14. • If more or less than the required amount of any of these
constituents exist, it may cause serious damage to the
brick.
•The composition is lightly bonded in the case of regular
bricks, whereas firebricks are much more dense.
•Flint Clay or Grog (Fire Clay) are used as Non–Plastic
Materials.
• Soft Fire Clay is used as Plastic Material

15. Flint ClayFire Clay

16. SAND LIME BRICKS
• Calcium silicate bricks are made of sand and lime and popularly known as sand lime
bricks.
•The Materials listed below are used for the production of calcium silicate bricks.
1. Sand
2. Lime
3. Water
4. Pigment

17. SAND
• Calcium silicate bricks contains high amount of sand is about 88 –
92%. It means the properties of these bricks depends upon the
characteristics of sand used.
•So, the sand used shall be well graded and should not contain any
impurities like organic matter, soluble slats etc.
•The finely divided clay may be present but it is up to 4% only which
helps the brick in pressing and provides smoother texture.

18. LIME
• Lime content in calcium silicate bricks varies from 8 to 12%. The lime used shall be of
good quality and high calcium lime.
WATER
• Clean water should be used for preparing calcium silicate bricks.
• Sea water or water containing soluble salts or organic matter more than 0.25% are
not suitable.

19. PIGMENTS
• Pigments are generally used to give color to the bricks. They are added to the sand
and lime while mixing.
•Total weight of brick contains 0.2 to 3 % of pigment quantity. Different pigments used
to get different colors are tabulated below:
PIGMENT COLOUR
Carbon black Black, Grey
Iron oxide Red, Brown
Chromium oxide Green
Ochre Yellow

21. COMPARISON
FIRE BRICKS SAND LIME BRICKS
Silica
Alumina
Lime
Sand
Magnesia
Iron Oxide
Alkalies
Lime
Flint Clay or Grog (Fire Clay) are
used as Non–Plastic Materials.
Water
Soft Fire Clay is used as Plastic
Material.
Pigments

22. MANUFACTURING
PROCESS
Chetan Sharma

23. STAGES
Stage 1. Selection of the suitable type of Brick Earth.
Stage 2. Preparation and Tempering of Mud.
Stage 3. Shaping or Molding of brick units.
Stage 4. Drying of molded bricks.
Stage 5. Cooling and Burning of bricks.

24. Selection of the Suitable Type of
Brick Earth
Good quality building bricks can not be made from every type of earth or soil.
This is, however, a general statement. A suitable earth should have various
constituents in the following proportions :
1. Alumina (20-30%)
2. Silica (50-60%).
3. Lime (4%)
4. Iron Oxide (4-6%)
Magnesia, which is invariably associated with lime, also has a similar effect. It
is their total percentage which must be considered while determining the
composition of the brick earth

25. • A shortage of iron oxides in the earth will affect the final color of the
bricks : instead of being brick red, they may be yellow or light red.
• Besides the above desired essential constituents of good brick earth,
there are some materials which should not be present in the good quality
brick earth at all, even in a small percentage.
They are listed below with their harmful effects.
(1) Lime Nodules. Free lime nodules will hinder in proper burning. They will
also adversely affect the quality of final brick.
(2) Organic Matter. This includes roots of grasses, leaves and other
vegetable matter. Such matter will affect the quality of brick if left
incompletely burnt during the process.
(3) Sulphides and Sulphates. Iron sulphide in the form of Pyrite and alkalies
in the form of potash and soda are some other common impurities present
in many soils.

26. Preparation and Tempering of
Mud
• A series of steps are necessary before the earth is ready for moulding of bricks.
• The area selected for the brick-earth is first cleaned or unsoiled at the top.
• From this cleared area brick-earth is obtained by:
1. Surface digging, by using hand tools
2. Mechanical excavation, by using heavy machines called excavators.
• Any clay lumps are broken into a fine powder so that a uniform-sized seasoned
earth is prepared.
• Tempering is done i.e. converting of the prepared brick earth into a
homogeneous mix of the desired plasticity by mixing it thoroughly with proper
quantities of water.

27. Shaping or Molding of brick units
Molding is the process of making properly shaped brick units from a
thoroughly tempered clay. There are two main methods of molding:
1. Hand Molding: When the job is done by skilled persons
2. Machine Molding: When specially designed machines are used for
moulding of bricks.
3. Dry Press Process : In this method, only a very small quantity of water is
added to finely crushed and thoroughly cleaned clay.

28. Drying of Molded Bricks
After molding, the green bricks have to be dried. This is necessary for
three reasons. . .
1. To make them strong enough for rough handling during subsequent
stages
2. To allow a slow loss of moisture from the brick without disintegrating
the unit.
3. To save fuel during the burning stage, a brick containing 20 percent
moisture will require more fuel to burn compared to a brick
containing only 2-4 percent moisture.

29. •In the natural drying method, there are two distinct stages :
• Pre-stacking stage, where the molded bricks are first laid edgewise, side-wise
and flat for 2-3 days so that they become hard-enough to handle without losing
shape or breaking.
• Stacking Stage, in which the hard bricks from the first stage are arranged in
well-made layers, one layer above another.
• Artificial drying may be done either in specially designed chambers or in
tunnels.
• Use of sun-dried Bricks : The sun-dried bricks, also called ADOBE are poor man’s
construction material even during the present time in many countries of the
world.

30. Cooling and Burning of bricks
•Dehydration. It is completed within the temperature range of 425 – 750° C. Bricks
heated to this temperature lose all the free water.
•Oxidation. It also starts within the above range or temperature and is completed at
about 900°C. All the organic matter in the brick-earth gets oxidized; carbon and
sulphur are eliminated as oxides. The fluxes ( lime, magnesia, and iron) also become
reactive at this temperature. The brick acquires the red color due to oxidation of
iron in the clays.
•Vitrification is the extreme reaction that takes place from 900°C to 1100°C or so.
The constituents of brick clay, that is alumina and clay, start softening in the
presence of fluxes and getting bound together firmly.
• Cooling: In this stage of manufacturing of bricks, The burnt bricks are placed for
some time to be cooled before using it in the construction.

32. TYPES OR
CLASSIFICATIONS
Aditya Patyal

33. Classification of Bricks Based on
Quality
• First Class Brick: The size is standard. The color of these bricks is uniform yellow or red. It is well
burnt, regular texture, uniform shape. The absorption capacity is less than 10%, crushing strength is,
280kg/cm2 (mean) where it is 245 kg/cm2 (minimum). It doesn’t have efflorescence. It emits a metallic
sound when struck by another similar brick or struck by a hammer. It is hard enough to resist any
fingernail expression on the brick surface if one tries to do with a thumbnail. It is free from pebbles,
gravels or organic matters.
• Second Class Brick: The size is standard, color is uniform yellow or red. It is well burnt, slightly over
burnt is acceptable. It has regular shape; efflorescence is not appreciable. The absorption capacity is
more than 10% but less than 15%. Crushing strength is 175kg/cm2(mean) where the minimum is 154
kg/cm2
•Third Class Brick: The shape and size are not regular. The color is soft and light red colored. It is under
burnt, slightly over burnt is acceptable. It has extensive efflorescence. The texture is non-uniform. The
absorption capacity is more than 15% but less than 20%. The crushing strength is 140kg/cm2(mean)
where the minimum crushing strength is 105kg/cm2. It emits a dull or blunt sound when struck by
another similar brick or struck by a hammer. It leaves fingernail expression when one tries to do with
the thumbnail.

34. Classification of Bricks Based on
Building Process
On the basis of the building process Bricks are of following kinds:
1. Unburnt Bricks: These are half burnt bricks. The color is yellow. The strength is low.
They are used as surki in lime terracing. They are used as soiling under RCC footing or
basement. Such bricks should not be exposed to rainwater.
2. Burnt Bricks: Burnt bricks are made by burning them in the kiln. First class, Second
Class, Third Class bricks are burnt bricks.
3. Over Burnt or Jhama Brick: It is often known as the vitrified brick as it is fired at high
temperature and for a longer period of time than conventional bricks. As a result, the
shape is distorted. The absorption capacity is high. The strength is higher or
equivalent to first class bricks. It is used as lime concrete for the foundation. It is also
used as coarse aggregate in the concrete of slab and beam which will not come in
contact with water.

35. Classification of Bricks Based on
Manufacturing Method
On the basis of manufacturing method bricks are of following kinds:
1. Extruded Brick: It is created by forcing clay and water into a steel die, with a very
regular shape and size, then cutting the resulting column into shorter units with wires
before firing. It is used in constructions with limited budgets. It has three or four holes
constituting up to 25% volume of the brick.
2. Molded Brick: It is shaped in molds by hand rather being in the machine. Molded
bricks between 50-65mm are available instantly. Other size and shapes are available in
6-8 weeks after the order.
3. Dry pressed Brick: It is the traditional types of bricks which are made by compressing
clay into molds. It has a deep frog in one bedding surface and shallow frog in another.

36. Classification of Bricks Based on
Their Using
There are many uses of bricks. On the basis of the purpose of their using bricks are of
following kinds:
1. Common Bricks: These bricks are the most common bricks used. They don’t have any
special features or requirements. They have low resistance, low quality, low
compressive strength. They are usually used on the interior walls.
2. Engineering Bricks: These bricks are known for many reasons. They have a high
compressive strength and low absorption capacity. They are very strong and dense.
They have good load bearing capacity, damp proof, and chemical resistance
properties. They have uniform red color. They are classified as Class A, class B, class C.
Class A is the strongest but Class B is most used. They are used for mainly civil
engineering works like sewers, manholes, ground works, retaining walls, damp proof
courses etc.

37. Classification of Bricks Based on
Shape
On the basis of shape bricks are of following:
1. Bullnose Brick
2. Airbricks
3. Channel Bricks
4. Coping Bricks
5. Cow Nose Bricks
6. Capping Bricks
7. Brick Veneers
8. Curved Sector Bricks
9. Hollow Bricks
10. Paving Bricks
11. Perforated Bricks
12. Purpose Made Bricks

38. Classification of Bricks Based on
Using Location
On the basis of using location bricks are of following kinds:
1. Facing Brick: The façade material of any building is known as facing brick. Facings
bricks are standard in size, are stronger than other bricks and also have better
durability. The color is red or brown shades to provide a more aesthetic look to the
building. There are many types of facing bricks which use different techniques and
technology. Facing bricks should be weather resistant as they are most generally used
on the exterior wall of buildings.
2. Backing Brick: These types of brick don’t have any special features. They are just used
behind the facing bricks to provide support.

39. Classification of Bricks Based on
Weather-resisting Capability
On the basis of weather-resisting capability bricks are of following kinds:
1. Severe Weather Grade: These types of bricks are used in the countries which are
covered in snow most of the time of year. These bricks are resistant to any kind
of freeze-thaw actions.
2. Moderate Weather Grade: These types of bricks are used in the tropical
countries. They can withstand any high temperature.
3. No Weather Grade: These bricks do not have any weather resisting capabilities
and used on the inside walls.

40. USES
Ankush Dhaiya

41. Fire Brick Uses
• Kilns
Pottery kilns require very high temperatures
to properly vitrify the clay and make it non-
porous. Fire bricks are commonly employed as
either the entire kiln structure, or for the inner
layer of the kiln, where the most heat is
present. Higher alumina content bricks
(around 40 percent) are required for the inner
surface of kilns that need to fire raku ware and
stoneware, which reaches temperatures of
1,800 to 2,200 degrees Fahrenheit
respectively. Soft fire bricks are often used to
block up the kiln doors during firing, as they
are less durable for permanent construction,
and provide easily-removed insulation for the
kiln door.

42. Fire Brick Uses
•Fireplaces
Fireplaces often employ fire bricks in the inner
fire box to insulate against heat damage to
surrounding walls, and to keep the mantle and
outer fire place relatively cooler. For
fireplaces, fire bricks with alumina content of
around 18 to 20 percent are sufficient.

43. Fire Brick Uses
•Wood Fired Ovens
Wood-fired ovens, such as traditional pizza
ovens, commonly use fire bricks in the inner
construction around the oven chamber. Fire
bricks are used in the cooking floor as well as
the dome or roof of pizza ovens, and are able
to withstand the thermal cycling (rapid heat
up and cool down) that wood-fired ovens
experience. Using fire bricks in wood-fired
ovens makes the oven last a lot longer, and
they can easily withstand the average 900
degrees Fahrenheit that these ovens reach.

44. Fire Brick Uses
• Liners/Insulators
Fire bricks are used extensively as insulators and
liners in all kinds of wood-fire heaters, small
furnaces and even industrial-sized furnaces.
Refractory bricks, as fire bricks are sometimes called,
are used in blast furnaces because they have low
thermal conductivity and insulate the heat from the
furnace, providing the double benefit of making the
furnace hotter and more efficient, as well as
protecting the outside of the furnace from excess
heat.

45. Sand Lime Bricks Uses
There are many advantages of calcium silicate bricks when used in masonry
construction, and they are:
• Mortar required for providing plaster on calcium silicate bricks is very less
• Color and texture of these bricks is uniform.
• Compressive strength of sand lime bricks is about 10N/mm2. So, they are well
suitable for multi storied buildings.
• For constructions in clay soils, these bricks are more preferable.
• Trouble of Efflorescence does not arise in the case of sand lime bricks.
• Not only bricks, blocks and tiles can also be made using calcium silicate.

46. •Sand lime bricks provides more comfort and accessibility for architects to
attain desired shape and designs.
•These bricks have accurate shape and size with straight edges.
•Solar heat effect is reduced on exposed walls made of calcium silicate
bricks.
•Colored sand lime bricks do not need any finish to the wall, so, cost
reduces.
•These bricks have great fire resistance and water repellant properties.
•Calcium silicate brick walls resists noise from outside.

47. MASONRY/ HOW
TO USE
Aman Sihag

48. STEP-BY-STEP GUIDE TO LAYING
FIREBRICK
• CHOOSE YOUR FIREBRICK AND PATTERN
• MIX THE MORTAR
• ADD A SKIM COAT :- Once you’ve mixed your mortar, you’ll need to add a skim coat
of mortar to the back wall of the firebox. Doing this removes any air gaps, as well as
provides an added layer of heat protection.

49. • LAY THE FLOOR:- Before you lay any bricks, make sure to set up your spacing guides –
these should be placed so that a ½” expansion gap is left off the back and side walls.
This expansion gap gives the firebrick room to expand and contract as it heats up and
cools down.
• LINE THE BACK WALL
• LINE THE SIDE WALLS
• CLEAN UP :- As you apply your firebrick, you should scrape away any excess mortar
that oozes out from between the bricks. However, simply scraping away the mortar is
not enough to give the joints a smooth, finished appearance.

50. Brick Masonry Construction
Procedure
1. Initially, mix the mortar with water and blend it until a smooth and plastic mortar is
produced.
2. After that, place the mortar on foundation line evenly using trowel (25mm
thickness and one brick wide is recommended for laid mortar).
3. Then, lay the first course of stretcher bricks in the mortar. Start with second brick,
apply mortar to the head joint end of each brick, After that shove the bricks into
place firmly so that the mortar is squeezed out of all side of the joints.
4. Utilize a level to examine the course for correct height. ensure that bricks are
plumb and level.

51. 5. Place another mortar line alongside the first course, then begin laying the second
course.
6. Use the two half bricks to begin the second to ensure that the first two courses are
staggered for structural purposes.
7. To finish the second course of the lead, lay three header bricks and make sure that
they are plumb and level.
8. The third and fifth courses consists of stretchers similar to the first course. The
fourth course begins with single header, followed by stretchers. Use the level to
make sure that the lead is true on each course. Lastly, this pattern of brick laying is
used till the target height is reached.

52. Mortar Preparation Laying Bricks Plumb line of
brick masonry
Checking level of brick
masonry

53. REFRENCES
•https://en.wikipedia.org/wiki/Fire_brick
•https://en.wikipedia.org/wiki/Refractory
•http://www.carmeuse-construction.com/your-applications/building-materials/sand-
lime-bricks
•https://theconstructor.org/building/calcium-silicate-bricks-masonry-
construction/17256/
•https://civiltoday.com/civil-engineering-materials/brick/191-types-of-bricks
•https://civilseek.com/manufacturing-of-bricks/
•https://www.ehow.com/list_6523065_fire-brick-uses.html
•https://love.firerock.us/blog/step-by-step-guide-to-laying-firebrick