CONTENT

Page No.

1. INTRODUCTION 2-3
2. COMPOSITION 4-5
3. HARMFUL INGREDIENTS 6 - 7
4. MANUFACTURING 8-9
5. CLASSIFICATION 10-12
6. PROPERTIES 13
7. TESTING 14-16
8. DEFECTS 17-19
9. REFERENCES 20

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 1. INTRODUCTION
➢ Brick is most popular building material because it is cheap,
durable and easy to handle and work with.

➢ It is used for building-up exterior and interior walls, partition

walls, piers, footings and other load bearing structures.

➢ A brick is rectangular in shape and of size that can be

conveniently handled with one hand.

➢ 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:
▪ Length of brick = 2 x width of brick + thickness of mortar
▪ Height of brick = width of brick

➢ Size of a standard brick (also known as modular brick) should

be 19 x 9 x 9 cm and 19 x 9 x 4 cm. When placed in masonry
the 19 x 9 x 9 cm brick with mortar becomes 20 x 10 x 10 cm
(Nominal Size).

➢ The bricks available in most part of the country still are 9" are
known as field bricks or non-modular bricks.

➢ Mass of such brick is about 3 to 4 kg.

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 Fig.1

➢ An indent called frog, 1-2 cm deep, as shown in Fig.1 is

provided for 9 cm high bricks and the size of frog should be
10 x 4 x 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.

Fig.2 (a) : NON-MODULAR BRICK Fig.2 (b) : MODULAR BRICK

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 2. COMPOSITION

SILICA 50 - 60 %
ALUMINA 20 -30 %
LIME 10 %
MAGNESIA < 1%
FERRIC OXIDE <7% Less than 20%

ALKALIS < 10 %
CARBON DIOXIDE
SULPHUR TRIOXIDE Very Small Percentage

WATER

I. SILICA :
▪ It helps brick to retain its shape, imparts durability, and
prevents shrinkage, cracking and warping.
▪ Excess of silica destroys cohesion between particles and
bricks become brittle and weak on burning.

II. ALUMINA :
▪ It absorbs water and impart plasticity to clay so that the
bricks can be moulded.
▪ If alumina is present in excess, it causes cracks in bricks
on drying and bricks become when burnt.
▪ Clays having high alumina are found be refractory.
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III. LIME :
▪ Reduces shrinkage on drying.
▪ Causes silica in clay to melt on burning and this helps to
bind brick particles.
▪ In carbonated form, lime lowers the fusion point.
▪ Excess of lime causes the brick to melt and the brick
looses its shape.

IV. IRON OXIDE :

▪ Gives strength and hardness.
▪ mproves permeability and durability.
▪ Gives red colour on burning when excess of oxygen is
available and dark brown or even black colour when
oxygen available is insufficient.
▪ Excess of ferric oxide makes brick dark blue, lesser makes
it yellow in colour.

V. MAGNESIA :
▪ A small quantity of magnesia in brick earth imparts
yellow tint to the bricks and decrease shrinkage.
▪ It slow down the rate of softening of clay during buming
and reduces warping.
▪ Excess of magnesia leads to decay of bricks

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 3. HARMFUL INGREDIENTS IN
EARTH BRICK

I. LIME :
▪ Lumps of lime (limestone, kankar) are converted into
quick lime after buming and this quick lime slakes and
expands in presence of moisture causing disintegration
of bricks.
▪ Hence lime should be present in finely divided state and
lumps should be removed in the beginning itsell.

II. IRON PYRITES :

▪ Iron pyrites get oxidized in the brick, crystallize and split
the brick to pieces.
▪ It also decolourise the brick.

III. Alkalles :
▪ They are mainly present in the form of soda and potash,
during burning of brick is acts as a flux.
▪ Alkalies in excess melts the clay on burining and make
bricks loose their shape.

IV. PEBBLES , GRAVEL , GRITS :

▪ It does not allow clay to be mixed uniformly and
thoroughly which will result in weak and porous bricks.

V. ORGANIC MATTER :
▪ Presence of organic matter in the raw material assist in
buming But if it is not completely burnt, the brick

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 becomes porous due to entrapment of gases evolved by
burning of carbonaceous matter.
▪ Hence, thorough burning of brick is necessary.

VI. SULPHUR :
▪ If sulphur is present in brick earth and insufficient time is
given during tuming for propter oxidation of carbon and
sulphur then sulphur will cause the formation of spongy
swollen structure on the brick and the brick will be
decoloured by white blotches.

VII. WATER :
▪ A large amount of free water causes shrinkage water
causes shrinkage during buming of brie on drying
whereass large amount of combined water causes
shrinkage during burning.

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 4. MANUFACTURING OF CLAY
BRICKS

Fig.3 : FLOW CHART MANUFACTURING OF CLAY BRICKS

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I. Preparation of Clay or Brick earth :
▪ UNSOILING : To remove impurities of organic matter in
top soil up to 20 cm.
▪ Digging : Clay is dug out & laid on leveled ground a little
below the general surface.
▪ Cleaning : stone, vegetable matter removed.
▪ Weathering : cleaned earth is spread and exposed to
weather for few months.
▪ Blending : mixing of clay/sand/other material.
▪ Tampering : water is added to clay and it is kneaded.

II. MOULDING :
▪ Hand moulding.
▪ Machine moulding.

III. Drying:
▪ 7 to 14 days.

IV. Burning at 750 C to 1000 C.

▪ Clamp burning
▪ Kiln burning
i. Clamp Burning:-
• are under No control on burning.
• Bottom bricks are over burnt hence become brittle.
• Top bricks burnt hence become soft.
ii. Kiln burning:-
• Better control on burning.
• Gives good quality bricks.
• It gives better hardness and strength to bricks.
• Bricks are more dense & durable.

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 5. CLASSIFICATION OF BRICKS

I. ON THE BASIS OF FIELD PRACTICE :

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

A. FIRST CLASS BRICK –

▪ These are thoroughly burnt and are of deep red, cherry or
copper colour.
▪ Surface should be smooth and rectangular with parallel,
sharp and straight edges and square corners.
▪ It should be free from flaws, cracks and stones.
▪ It should have uniform texture.
▪ No impression should be left on bricks when scratched by
finger nail.
▪ Fracture surface of the brick should not show lumps of
lime.
▪ Metallic ringing sound should come when two bricks are
struck.
▪ Water absorption not more than 12-15% of its dry weight
when immersed in cold water for 24 hours.
▪ Compressive strength = 10.5 N/mm².
▪ Uses : First class brick are recommended for exposed face
work in masory structures, flooring and reinforced brick
work.

B. SECOND CLASS BRICK –

▪ These bricks have same requirements as first class bricks
except for the listed below.
▪ Small cracks and distortions are permitted.

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 ▪ Water absorption not more than 16-20% of its dry weight
when immersed in cold water for 24 hours.
▪ Compressive strength = 7 N/mm².
▪ Uses : Second class bricks are recommended for all
important or unimportant hidden masonry works.

C. THIRD CLASS BRICK –

▪ These bricks are soft and reddish yellow coloured (under
burnt).
▪ Dull sound when struck with each other.
▪ Water absorption is about 25% of dry weight.
▪ Rough surface with irregular and distorted edges.
▪ Uses : For building temporary structures and at places
where rainfall is not heavy.

D. FOURTH CLASS BRICK –

▪ Over burnt and badly distorted in shape, sizes, and brittle
in nature.
▪ Uses : Ballast of such bricks is used for foundations and
floors in lime concrete and road metal, because burnt
bricks have compact structures and found to be a stronger
than even first class bricks.

Fig.4 (a) : First Class Bricks Fig.4 (b) : Second Class Bricks

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 Fig.4 (c) : Third Class Bricks Fig.4 (d) : Fourth Class Bricks

II. ON THE BASIS OF STRENGTH(IS 1077 : 1992) :

➢ On the basis of strength bricks are classified as follows

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 6. PROPERTIES OF GOOD EARTH
BRICKS
I. SIZE AND SHAPE :
▪ Bricks should have uniform size and plane rectangular
surface with parallel and sharp straight edges.

II. COLOUR :
▪ Brick should have uniform deep, red or cherry colour as
indicative of uniformity in chemical composition and
thoroughness in the burning of brick.

III. TEXTURE AND COMPACTNESS :

▪ Surface should not be too smooth to cause slipping of
mortar. The brick should have uniform rough texture.
When broken or fractured should show a bright,
homogeneous and uniform compact structure free from
voids.

IV. HARDNESS :
▪ No impression should be left when scratched by finger
nail.

V. SOUNDNESS :
▪ Metallic sound should be produced when two bricks are
struck.

VI. WATER ABSORPTION :

▪ Should not exceed 20% of its dry weight when kept
immersed in water for 24 hours.

VII. CRUSHING STRENGTH :

▪ Crushing strength > 10 N/mm²

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 7. TESTING OF BRICKS

➢ A brick is generally subjected to following test to find out its

suitability for the construction work

I. COMPRESSIVE STRENGTH TEST (IS 3495 (Part 1)) :

▪ Compressive strength of bricks provides comparison of
quality of bricks.
▪ Remove unevenness observed in the bed faces to provide
two smooth and parallel faces by grinding.
▪ Immerse in water at room temperature for 24 hours.
▪ Remove specimen and wipe out surplus water on the
surfaces.
▪ The frog and all the voids in the bed face are flushed level
with cement mortar.

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 ▪ It is then stored under damp jute bags for 24 hours
followed by immersion in clean water for 3 days.
▪ After the load is applied axially at a uniform rate of 14
MPa/min till failure occurs and maximum load at failure
is noted.

▪ Compressive strength = Maximum load at failure

Loaded area of brick

▪ The compressive strength of individual brick testing in

the sample should not fall below the minimum average
compressive strength specified for the corresponding
class of brick by more than 20%.

II. WATER ABSORPTION TEST (IS 3495 (Part 2)) :

▪ Water absorption of bricks depend on their porosity.
Almost all the bricks absorbs water by capillary action.
▪ % of water absorption gives indication of compactness
which vitrification in real sense). is obtained from
burning
▪ Method: 24 hours immersion cold water test
▪ Dry bricks are kept in oven at 110 ± 5°C.
After cooling the bricks to room temperature weight is
recorded as W1. Now bricks are immersed in water at a
temperature of 27 ± 2°C for 24 hours.
▪ Bricks are taken out of water, wiped with a damp cloth
and weight recorded as W₂.

▪ The water absorption in % (W24) = W2 - W₁

W1

▪ NOTE :
• Bricks are soaked in water before use in masonry work
so that they do not absorb water from mortar.

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• Average water absorption < 20% upto class 12.5 and 15%
for higher classes.
• For water absorption < 5%, danger of frost
action is negligible.

Fig.5 (a) : Compressive strength test

Fig.5 (b) : Water Absorption Test

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 8. DEFECTS OF BRICKS

I. OVER-BURNING BRICKS :
▪ If the bricks are overburnt, a soft molten mass is
produced, and bricks loose their shape. Such bricks
are not used for construction works.

II. UNDER-BURNING BRICKS :

▪ When bricks are not burnt properly, the clay is not
softened because of insufficient heat and the pores
are not closed.
▪ This results in higher degree of water absorption
and less compressive strength.
▪ Such bricks are not recommended for construction
works.

III. BLOATING :
▪ This defect is observed as spongy swollen mass over the
surface of burned brick.
▪ It caused due to presence of excess carbonaceous
matter and sulphur in brick clay.

IV. BLACK CORE :

▪ When the bricks contains bituminous matter or carbon
and they are not completely removed by oxidation,
which results in black core mainly because of improper
burning.

V. CHUFFS :
▪ Chuffs is deformation in shape of bricks due to
rainwater falling on hot bricks.
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VI. EFFLORESCENCE :
▪ This is caused because of alkalies present in bricks.
▪ These alkalies combine with sulphates from the
masonry to form sulphate salts. The alkali sulphates in
the wall are dissolved by water into a solution which
then moves through the natural pores in the masonry.
The solution migrates to the surface of the wall where
the water evaporates, depositing the salts on the wall
and generating the white powdery scum we know as
efflorescence.
▪ This can be reduced by selecting proper clay materials
for brick manufacturing, preventing moisture to come
in contact with the masonry by providing waterproof
coating and by using water repellent materials in
mortar and by providing damp proof course.

VII. CHECKS OR CRACKS :

▪ This is because of lumps of lime or excess of water.
▪ In case of lime, when bricks come in contact with water,
the absorbed water reacts with lime nodules causing
expansion and disintegration of brick whereas shinkage
and burning cracks results when excess water is added
during brick manufacturing.

VIII. SPOTS :
▪ If sulphide is present is present in the brick clay, it
causes dark surface.
▪ Such brick are not only harmful but also unsuitable for
exposed masonry work.

IX. BRICK SPALLING :

▪ Irregular portion of the brick break away of fall off.
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 ▪ Heating of water inside brick is the cause of spalling.

X. LAMINATIONS :
▪ Thin lamina is produced on the brick surface which flakes out on
exposure to atmospheric conditions.
▪ Lamination of brick is due to the entrapped air present in the
voids of clay. Bricks affected by lamination are weak.

Fig.6 (a) : Over-Burning Bricks Fig.6 (b) : Bloating

Fig.6 (c) : Spot Fig.6 (d) : Lamination

Fig.6 (e) : Black Core Fig.6 (f) : Spalling

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 9. REFERENCES
➢ CONSTRUCTION MATERIALS BY MADE EASY
PUBLICATION.

➢ BUILDING MATERIAL BY S K DUGGAL.

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