BRICKS

●​ Bricks are of the oldest building material brick continues to be a most popular and leading
construction material because of being cheap, durable and easy to handle and work with.
Clay bricks are used for building-up exterior and interior walls, partitions, piers, footings
and other load bearing structures.

●​ Brick may be made of burnt clay or mixture of sand and lime or of Portland cement
concrete. Clay bricks are commonly used since these are economical and easily available.

●​ The length, width and height of a brick are interrelated as below:

◊​ Size of a standard brick (also known as modular brick) should be 19 × 9 × 9 cm

◊​ When placed in masonry the 19 × 9 × 9 cm brick with mortar becomes 20 × 10 × 10
cm.
1
◊​ However, the bricks available in most part of the country still are 9" × 4 2 " × 3" and
are known as field bricks.

3
●​ Unit weight of brick masonry = 1920 kg/𝑚

●​ Weight of such a brick lies in range of is 3.0 to 3.5 kg.

●​ Frog: The central depression on the top of the brick is called frog. It is kept 1 to 2.5 cm
deep, is provided for 9 cm high bricks. The size of frog should be at least 10 × 4 × 1 cm.

◊​ The purpose of providing frog is to form a key for holding the mortar and therefore,
the bricks are laid with frogs on top.
◊​ Apart from providing a shear key, frog is used to engrave the signs on the bricks
which can be used to identify the manufacturer.

◊​ Frog is not provided in 4 cm high bricks and extruded bricks.

Classification of Bricks

Based on on-field Practices

●​ Clay bricks are classified as first class, second class, third class and fourth class based on
their physical and mechanical properties.

●​ First Class Bricks

◊​ These are thoroughly burnt and are of deep red, cherry or copper-coloured bricks.
◊​ The surface should be smooth and rectangular, with parallel, sharp and straight
edges and square corners.
◊​ These should be free from flaws, cracks and stones.
◊​ These should have uniform texture.
◊​ No impression should be left on the brick when a scratch is made by a finger nail.
◊​ The fractured surface of the brick should not show lumps of lime.
◊​ A metallic or ringing sound should come when two bricks are struck against each
other.
◊​ Water absorption should be 12–15% of its dry weight when immersed in cold water
for 24 hours.
2
◊​ The crushing strength of the brick should not be less than 10 𝑁/𝑚𝑚 . This limit
varies with different Government organizations around the country.
◊​ Uses: First class bricks are recommended for pointing, exposed face work in
masonry structures, flooring and reinforced brick work.

●​ Second Class Bricks

◊​ These are supposed to have the same requirements as the first-class bricks except
that small cracks and distortions are permitted.
◊​ A little higher water absorption of about 16–20% of its dry weight is allowed.
2
◊​ The crushing strength should not be less than 7.0𝑁/𝑚𝑚 .
◊​ Uses: Second class bricks are recommended for all important or unimportant
hidden masonry works and reinforced cement concrete (RCC) structures.

●​ Third Class Bricks

◊​ These are under burnt.

◊​ They are soft and light-colored producing a dull sound when struck against each
other.
◊​ Water absorption is about 25 per cent of dry weight.
◊​ Uses: It is used for building temporary structures.

●​ Fourth Class Bricks

◊​ These are over burnt and badly distorted in shape and size and are brittle in nature.
 ◊​ Uses: The ballast of such bricks is used for foundation and floors in lime concrete
and road metal.

Classification based on Strength Criteria

●​ The Bureau of Indian Standards (BIS) has classified the bricks on the basis of compressive
strength as given based on IS 1077:

Average Compressive Strength not Average Compressive Strength not

Class 2 Class 2
less than (in 𝑁/𝑚𝑚 ) less than (in 𝑁/𝑚𝑚 )

35 35. 0 12. 5 12. 5

30 30. 0 10 10. 0
25 25. 0 7. 5 7. 5
20 20. 0 5 5. 0
17. 5 17. 5 3. 5 3. 5
15 15. 0

Characteristics of good Bricks

●​ Size and Shape: The bricks should have uniform size and plane, rectangular surfaces with
parallel sides and sharp straight edges.

●​ Color: The brick should have a uniform deep red or cherry color as indicative of uniformity
in chemical composition and thoroughness in the burning of the brick.

●​ Texture and Compactness: The surfaces should not be too smooth to cause slipping of
mortar.

●​ The brick should have pre-compact and uniform texture. A fractured surface should not
show fissures, holes grits or lumps of lime.

●​ Hardness and Soundness: The brick should be so hard that when scratched by a finger
nail no impression is made. When two bricks are struck together, a metallic sound should
be produced.

●​ Water absorption: Should not exceed 20% of its dry weight when kept immersed in water
for 24 hours.

2
●​ Crushing Strength: Should not be less than 10 𝑁/𝑚𝑚 .
Manufacturing of Burnt Clay Bricks

Brick Clay

●​ For the preparation of bricks, clay or other suitable earth is moulded to the desired shape
after subjecting it to several processes.

●​ Characteristics of good quality brick clay:

◊​ After drying, it should not shrink and no crack should develop.

◊​ The clay used for brick making consists mainly of silica and alumina mixed in such a
proportion that the clay becomes plastic when water is added to it.
◊​ It also consists of small proportions of lime, iron, manganese, Sulphur, etc.

●​ Proportions of various ingredients in brick clay:

Ingredients Percentage

Silica 50 − 60%
Alumina 20 − 30%
Lime 10%
Magnesia < 1%
Ferric Oxide < 7% {𝐿𝑒𝑠𝑠 𝑡ℎ𝑎𝑛 2
Alkalis < 10%
Carbon Dioxide

Sulphur Trioxide { 𝑉𝑒𝑟𝑦 𝑆𝑚𝑎𝑙𝑙 𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒

Water

Functions of various Ingredients in Brick Clay

●​ Silica

◊​ It enables the brick to retain its shape and imparts durability, prevents shrinkage
and warping.
◊​ Excess of silica makes the bricks brittle and weak on burning.
◊​ A large percentage of sand or uncombined silica in clay is undesirable.
◊​ However, it is added to decrease shrinkage in burning and to increase the
refractoriness of low alumina clays.
 ●​ Alumina

◊​ It absorbs water and renders the clay plastic.

◊​ If alumina is present in excess of the specified quantity, it produces cracks in brick
on drying.
◊​ Clays having exceedingly high alumina content are likely to be very refractory.

Refractory Material or refractory is a material that is resistant to decomposition by

heat, pressure, or chemical attack, and retains strength and form at high
temperatures.

●​ Lime: It normally constitutes less than 10 per cent of clay. Lime in brick clay has the
following effects:

◊​ It reduces the shrinkage on drying.

◊​ It causes silica in clay to melt on burning and thus helps to bind it.
◊​ In carbonated form, lime lowers the fusion point.
◊​ Excess of lime causes the brick to melt and the brick loses its shape.

●​ Magnesia

◊​ It rarely exceeds 1 per cent. It affects the color and makes the brick yellow, in
burning.
◊​ It causes the clay to soften at slower rate than in most case is lime and reduces
warping.

●​ Iron Oxide: Iron oxide constituting less than 7 per cent of clay, imparts the following
properties:

◊​ Gives red color on burning when excess of oxygen is available and dark brown or
even black color when oxygen available is insufficient, however, excess of ferric
oxide makes the brick dark blue.
◊​ Improves impermeability and durability.
◊​ Tends to lower the fusion point of the clay, especially if present as ferrous oxide.
◊​ Gives strength and hardness.

Harmful Substances in Brick Clay

●​ Pebbles, Gravels & Grits: do not allow the clay to be mixed thoroughly and spoil the
appearance of the brick. Bricks with pebbles and gravels may crack while working.

●​ Iron Pyrites: tend to oxidize and decompose the brick during burning. The brick may split
into pieces. Pyrites decolorize the bricks.
 ●​ Alkalis: When present in excess, alkali makes the clay unsuitable for bricks. They melt the
clay on burning and make the bricks unsymmetrical.

When bricks come in contact with moisture, water is absorbed and the alkalis crystallize.
On drying, the moisture evaporates, leaving behind grey or white powder deposits on the
brick which spoil the appearance. This phenomenon is called efflorescence.

Efflorescence should always be dry brushed away before rendering or plastering a wall;
wetting it will carry the salts back into the wall to reappear later. If bricks become saturated
before the work is completed, the probability of subsequent efflorescence is increased,
brick stacks should, therefore be protected from rain at all times.

During laying, the bricks should be moistened only to the extent that is found absolutely
essential to obtain adequate bond between bricks and mortar.

●​ Organic Matter: On burning green bricks, the organic matter gets charred and leave pores
making the bricks porous; the water absorption is increased and the strength is reduced.

●​ Carbonaceous Material: in the form of bituminous matter or carbon greatly affects the
color of raw clay. Unless proper precaution is taken to effect complete removal of such
matter by oxidation, the brick is likely to have a black core.

Process of Brick Manufacturing

●​ Steps involved in manufacturing of bricks:

i)​ Preparation of clay

ii)​ Moulding
iii)​ Drying
iv)​ Burning

●​ Preparation of Clay:

i)​ Unsoiling: Process of removal of top surface of soil.

ii)​ Excavation

iii)​ Cleaning

iv)​ Weathering: Soil after cleaning is placed in open atmosphere and is levelled on
ground. This batch of earth will be turned regularly for 1 to 2 months.

v)​ Blending: Addition of proportion of ingredients required to obtain suitable ratio.

 vi)​ Tempering: Addition of water and making the clay suitable for moulding using pug
mill.

●​ Moulding of Bricks: Size of the brick moulds is usually 8 to 10% more than that of the
size of actual brick. Moulds which can be used for moulding of bricks can be of two types:

i)​ Wooden Mould

ii)​ Steel Mould

●​ Drying: Natural air drying is highly recommended. Rapid air drying or direct burning may
lead to excessive shrinkage. Drying should be done up to shrinkage limit of brick soil.

●​ Burning of Brick: Burning temperature for the bricks should lie in a range of 800°C to
1200°C. Optimum temperature for burning is considered to be 900°C. Burning in the most
important operation of brick manufacturing and is required to be done up to optimum level;
there should neither be over-burning nor there should be under-burning of the bricks.
◊​ Down Draught Kilns will produce better quality bricks as compared to up-draught
kilns.
◊​ Intermittent Kilns can’t insure daily production output of bricks.
◊​ Continuous Kilns can insure continuous daily output of bricks:

i)​ Bull trench Kiln: Oval shaped kiln with multiple chamber and oval shape.

ii)​ Hoffmann’s Kiln: Down-draught arrangement with circular plan and

non-moving state. Very useful for large scale production and provides better
quality than that of Bull Trench Kiln.
 iii)​ Tunnel Kiln: For large scale production only.

𝐿𝑜𝑎𝑑𝑖𝑛𝑔⟶𝑃𝑟𝑒ℎ𝑒𝑎𝑡𝑖𝑛𝑔 𝑍𝑜𝑛𝑒 ⟶𝐵𝑢𝑟𝑛𝑖𝑛𝑔 𝑍𝑜𝑛𝑒 ⟶𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝑍𝑜𝑛𝑒 ⟶𝑈𝑛𝑙𝑜𝑎𝑑𝑖𝑛𝑔

Testing of Clay Bricks (IS 1077 and IS 3495)

Dimension Test

●​ Bricks should have sharp edges, uniform colour and proper dimension:

𝑆𝑡𝑎𝑛𝑑𝑎𝑟𝑑 𝐷𝑖𝑚𝑒𝑛𝑠𝑖𝑜𝑛 ⇒19𝑐𝑚 * 9𝑐𝑚 * 9𝑐𝑚

𝐶𝑜𝑛𝑣𝑒𝑛𝑡𝑖𝑜𝑛𝑎𝑙 𝐷𝑖𝑚𝑒𝑛𝑠𝑖𝑜𝑛 ⇒23𝑐𝑚 * 11. 4𝑐𝑚 * 7. 6 𝑐𝑚

Structure Test

●​ Brick is broken into two parts and the interior of the brick is observed. There should be
homogenous and uniform colour. The brick should be free from cracks or voids nd their
weight should be between 3 kg and 3.5 kg.

Compressive Strength Test

 ●​ A plywood is place between the plates of the machine and the brick faces in UTM.
●​ Bricks are loaded at 14 N/mm2/min.
●​ As per IS 1077, minimum compressive strength = 3.5 MPa.

Water Absorption Test

●​ Bricks are oven dried at 100°C and dry weight is noted 𝑤1 .

( )
●​ Bricks are then soaked for 24 hours and then weighed (𝑤2).

(𝑤2−𝑤1)
𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝐴𝑏𝑠𝑜𝑟𝑝𝑡𝑖𝑜𝑛 =
(𝑤1) * 100

Bricks Heavy
First Second Third Refractory
Brick Type greater than Duty
Class Class Class Bricks
grade 12.5 Bricks

Maximum
Permissible Moisture 20% 22% 25% 15% 5% 5%
absorption

Other Tests on Bricks

●​ Alkali Test/ Efflorescence Test

●​ Soundness Test: Two bricks when struck together shouldn’t break and should produce
clear ringing sound.

●​ Toughness Test: Brick when dropped from approximately 1-meter height shouldn’t break.

●​ Hardness Test: Brick when scratched with finger nail shouldn’t have any sign of
scratching.

Special Bricks

Refractory Bricks (Fire Bricks)

●​ To produce Refractory bricks, fire clay or high alumina clay is used.

●​ These bricks use to have light colour and higher strength and can bear a temperature of
1700°C.
 ◊​ Acidic Refractory Bricks: Prepared by raising silica content and are used when the
structure is prone to acidic environment.

◊​ Basic Refractory Bricks: Prepared by raising magnesia content of the bricks and
are preferred where structure is prone to base attack.

◊​ Neutral Bricks: Produced by altering alumina content.

◊​ Chrome Brick = Chromium + Alumina + Iron Ore

Autoclave Bricks

●​ These are manufactured in autoclave oven.

●​ These are light weight, sound proof, insulating, heat resistant and fire resistant.
●​ Used in urban buildings of high value as these are costly.

Fly Ash Bricks

●​ These can be made using either C type fly ash or F type fly ash.

𝐶𝑜𝑚𝑝𝑜𝑠𝑖𝑡𝑖𝑜𝑛⇒{50 − 60% 𝐹𝑙𝑦 𝐴𝑠ℎ + 20 − 30% 𝑆𝑎𝑛𝑑 + 20 − 10% 𝐶𝑒𝑚𝑒𝑛𝑡 (𝐿𝑖𝑚𝑒 + 𝐺𝑦𝑝𝑠𝑢𝑚) }

●​ The above composition is processed through machine moulding and then pressure
application.

●​ Advantages:

◊​ Economical (15-20%)
◊​ Eco-friendly
◊​ Light Weight
◊​ Occurs in proper shape and size
◊​ Less moisture absorption
◊​ Dense

●​ Disadvantage: It may have less strength.

Brick Masonry (IS 2212)

●​ Important Terminologies:

◊​ Stretcher: Long side face

◊​ Header: Short side face
 ◊​ Other important terms:

Bonds in Brick Masonry

●​ Objective of choosing any particular brick masonry is to provide maximum strength to the
structure with best possible appearance.

Stretcher Bond

●​ Stretcher face in each layer; ①-②-①-② system.

●​ Half bat is used at the ends.
𝑀𝑖𝑛 𝑊𝑎𝑙𝑙 𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 𝐻𝑎𝑙𝑓 𝐵𝑟𝑖𝑐𝑘 𝑇ℎ𝑖𝑐𝑘

Header Bond

●​ Header on the face.

3
●​ End brick = 4
bat.
𝑀𝑖𝑛 𝑊𝑎𝑙𝑙 𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 𝑂𝑛𝑒 𝐹𝑢𝑙𝑙 𝐵𝑟𝑖𝑐𝑘 𝑇ℎ𝑖𝑐𝑘
English Bond

●​ Alternate header and stretcher coarse.

●​ In header coarse, we provide a queen closer at ends.

𝑀𝑖𝑛 𝑊𝑎𝑙𝑙 𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 𝑂𝑛𝑒 𝐹𝑢𝑙𝑙 𝐵𝑟𝑖𝑐𝑘 𝑇ℎ𝑖𝑐𝑘

Flemish Bond

●​ Alternate header and stretcher in each layer of brick.

●​ In alternate layers, queen closer is provided.
●​ Single Flemish Bond: Flemish bond on front and English bond on back.
●​ Double Flemish Bond: Flemish bond on both sides.
 1
●​ English Bond is considered strongest for 1 2
brick or above as Flemish bond has many
joints.

●​ Flemish Bond is a decorative bond and hence a skilled person is required for it.