Mud (clay) and its products

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 INTRODUCTION
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 Clay is a special kind of
earth which is made by the
decomposition (breakdown)
of rocks through the action
of weathering. -Primary
clay

 Clay that has been

transported from its
original site by water, air or
ice and deposited in layers
elsewhere- secondary clay
Clay products employed in building industry
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 Bricks

 Tiles

 Terracotta

 Earthenware

 Stoneware

 Porcelain
Building tiles
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 Tiles are thin slabs of brick earth, burnt in kiln.

These are thinner than bricks and have a greater
tendency to crack and wrap in drying and burning
than ordinary bricks and are more liable to breakage.

They should be dried in shade, burnt and cooled

gradually in specially made kilns.
Manufacture of Tiles:
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The manufacture of common tiles includes

1. Preparation of clay

2. Moulding of tiles

3. Drying of tiles

4. Burning of tiles.
1. Preparation of Clay:
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 Selected clay is made free from any impurity such as grit, pebbles.

 Clay is ground into powder in crushing roller and then thoroughly

pugged,

 For manufacture of superior tiles, powdered clay is mixed in large

quantity of water in tanks, well stirred up and then mixture is
allowed to settle

 Heavier and coarse particles sink to bottom of tank and finer

particles are run off into lower tank where matter is allowed to dry
leaving fine clay ready for mixing.
 The method is known as blunging process.
2. Moulding of tiles:
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Wooden patterns:
 Tiles which are not uniform in section throughout their entire
length are moulded in patterns (made of well seasoned wood).
 Flat cakes of clay are made and when partly dry, they are
moulded pressed and turned round a wooden pattern to give
them required shape.
Potter’s wheel:
 This method is similar to one that is adopted by a potter in
manufacture of earthenware vessels.
 This method is adopted when tile is of perfectly circular shape
 It may have diameter varying along its length.
Mechanical method:
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 This method of moulding is adopted for tiles having a

uniform section through-out their length.

3. Drying of tiles:
 Two days after moulding, tiles are slightly beaten with a
flat wooden mallet to correct irregularity in shape due to
wrapping.

 They are then left to dry for about 2 days under shade to
prevent wrapping and cracking when they are ready for
loading in kiln.
4. Burning of tiles:
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 Tiles are burnt in a typical kiln that can accommodate 30000 to 40000
tiles.
 A layer of bricks is laid flat on rows of long narrow fuels. The burning is
effected by firing wood placed in fuels.

 Doorways are the closed with bricks in mud plaster and top is covered
with old tiles and ash.

 Firing of kiln is started and fire is kept low till gases are driven out.
Temperature is then raised gradually till inner portions of fuels become
red hot (at about 800 degree Celsius).

 It is then slackened for about 6 hours, raised again, till the fuels are
white hot (at about 13000C) and kept as such for about 3 hours.
  Fire is again slackened for 6 hours, then increased once more to white
hot and kept steady for about 3 to 4 hours.
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 Finally fuels are filled and doorways are closed by brickwork in mud.
Kiln is then gradually allowed to cool down.
 Process of the burning tiles is completed in about 72 hours.

This process of burning has following advantages:

1. Drastic reduction of firing cycle from 72 hours to an average of just one

hours.

2. Reduced fuel consumption

3. Reduced total cost of production

4. Improved quality design etc of burnt tiles.

Characteristics of a good tile

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 It should possess uniform color.

 It should be properly burnt.
 It should be free from cracks, flaws or bends.
 It should be hard and durable.
 It should have proper shape and size.
 When placed in position, it should fit well.
 It should give a clear ringing sound when struck with light
hammer or with another tile.
Types of tiles
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 Roofing tiles

 Flooring tiles

 Wall tiles

 Drain tiles

 Glazed earthenware
tiles
 Roofing tiles:

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 These tiles are used to cover roof.
 As roofing tiles are placed exposed to atmosphere, these tiles
should be strong, durable and perfectly leak proof.
 They are expensive in initial cost but life cycle cost is less as
they need less maintenance.

1. Flat tiles:
 These tiles are rectangular in shape and are of various
dimensions.
 They are laid in cement or lime mortar.
 Different types of flat tiles are as follows:
 a. Slate tiles
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 Sizes available are 60cmx30cmx1,5cm and 50cmx25cmx1cm.

 These tiles should be straight uniform in color, texture, cracks,
white patches etc.
 Water absorption after 24 hours immersion in cold water
should be maximum 21% by weight.

 b. Burnt clay flat terracing tiles (Chinka appa)

 These tiles should be uniform in shape, size and free from

irregularities.
 Water absorption should not exceed 20% by weight.
 Compressive strength should not be less than 7.5 N/mm2.
 2.Pot tiles or country tiles:
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 These tiles are also sometimes called pan tiles.

 These tiles are semi-circular in section and are used either
alone or with flat tiles.
 These tiles are laid on sloped roofs along with concave side
up and longer end towards ridge. Then another row of same
tile with convex side up and small end towards ridge is laid
covering adjoining edges of every pair of tiles below
 These tile are extremely used in rural areas.
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Pot tiles
 3. Allahabad Tiles:
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 These tiles are of different shapes and are generally laid

side by side where joints are covered by half round tile.
 It should not absorb water more than 20% by weight.

 These tiles are used for making good and pleasing roofs.

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 4. Corrugated tiles:
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 These tiles have corrugation and when they are placed in

position a side lap of one or two corrugation is formed.
 Placing of such tiles on a roof gives an appearance of
galvanized sheet (CGI).
 They posses good appearance but is easily affected by air.
 Manglore tile:
 These tiles can be moulded by hand or by machine.

 They are flat and provided with suitable projections such that
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they interlock with each other, when placed in position.

 Ridge valley and lip tiles:

 Ridge tile is used in ridge of roof while valley tiles are used in
valley of roof. This tiles are made from good earth
 Flooring tiles:
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 These tiles are flat found commonly in square or
rectangular shape and can be made in any color and
shape.
 Ringing sound should emit when struck with each other
 Water absorption should be less than 24% by its weight
 Fractured surface of tile should be clean, dense and sharp
at edges.
 Common sizes of flooring tiles are 15cmx15cmx18mm
(LxBxH), 20cmx20cmx20mm, 22.5cmx22.5cmx22mm
Flooring tiles
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 Wall tiles:
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 These tiles are similar to floor tiles except for design and degree
of burning.
 They are burnt comparatively at a low temperature, glazed and
burnt again at a still lower temperature.
 They are found in different designs and colors and of any size.
 They are used on face work to some extent on arches, ceilings
etc.
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 Drain Tiles:
 These tiles are usually long curved sections of various shapes
and sizes such as semi-circular or segment of circle.
 They are generally used for graining waste water.

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 Other forms of clay product

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 Earthenware:
 The clay product which is manufactured from ordinary clay mixed
with sand, crushed pottery etc by burning at low temperature is
known as earthenware.
 They should not absorb water more than 18% by weight.

 Uses:
 They are used for making ordinary drain pipes, partition blocks
and electrical cable conduits.
 Glazed earthenware tiles are used in finishing floors and walls
of kitchen. Bathroom, hospitals, water closets etc.
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 Terra-cotta:
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 Terra-cotta is a kind of high quality earthen ware which is used

as a substitute for stone for ornamentation of building.
Advantages of terracotta:
 Can be cleaned easily
 Light in weight
 Strong and durable material
 Available in several colors.
 Can be moulded into desired shapes easily.
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 Uses:
 Used for ornamental works.
 Used as building material in form of shaped bricks.
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 Porcelain:
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 The term porcelain is used to indicate fine earthenware which is white,
thin and semi-transparent, sometimes referred as white ware.

 It is prepared from clay, flespar, quartz and minerals.

 Various types of porcelains available are used for various applications

such as sanitary wares, electric insulators etc.
Stoneware:
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 It is clay product manufactured from refractory clay mixed
with crushed pottery, powdered stone etc by burning at high
temperature.
 It is impervious to moisture, closed, grained, hard and
durable.
 It can be kept clean easily.
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 Uses:
 these are employed for Drain and sewer pipes Sanitary wares
 Vessels or jars to hold chemicals etc.
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 Glazing:
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 It is a process of forming some transparent film over
surface of bricks, tiles, earthenware/stoneware, to
improve appearance and also to protect from action of
weather, sewage, chemicals or destroying agents.

 It should be such that it should not form fine cracks on

surface when exposed to atmosphere.

 It may be transparent like glass or opaque like enamels.

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Thank you
 Types of process in cement manufacture

 Dry Process: The raw materials are ground, mixed and

fed in burning kiln in dry condition.

 Wet Process: Raw materials are subjected to kiln in wet

condition in form of slurry.

 Both are similar except that the raw materials are

ground, mixed and fed in kiln in dry condition in dry
process and wet in the form of slurry
 Dry Process
Used when raw materials are quite hard. It involves
following process
Mixing
 Raw materials (limestone+ clay) are ground separately
 Pug mill/ tube mill used for pulverization & checked by
sieve(100mesh)

 Burning
 Dry mixture fed to Rotary Kiln where it is burnt at 1500-
1700 C
 Clinker – product obtained after burning- size varies
from5mm-10mm
 Cooled clinkers are collected in container of suitable sizes
Grinding

 Clinkers ground to fine power

in ball mills and tube mills
after adding 3-4% of gypsum
 After that, packed and
distributed
2. Wet process

 Used when raw materials are quite soft

Mixing
• Crushed raw materials(limestone +clay) are mixed in wash mill in
desired proportion and then fed to ball mill.

• Little water is added to the mixture and mill is run for sometimes

• The mixture gets pulverized and forms into a solution called Slurry
• Collected slurry stored in storage tanks

• Composition of raw materials mix is better controlled in wet

process than in dry process.