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Clay Block

This document discusses clay blocks used in construction. It begins by introducing clay blocks and their composition of primarily silicon dioxide, aluminum oxide, and impurities. The manufacturing process is then outlined, involving preparing raw clay material, forming the blocks through extrusion or dry pressing, drying, firing in a kiln, and cooling. Defects and advantages of clay blocks are also noted. The document proposes using clay blocks as a filler material between reinforcement in concrete slabs, listing considerations for suitable filler materials. Installation details and cost savings compared to solid concrete slabs are provided.

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Nidhi Mehta
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
399 views20 pages

Clay Block

This document discusses clay blocks used in construction. It begins by introducing clay blocks and their composition of primarily silicon dioxide, aluminum oxide, and impurities. The manufacturing process is then outlined, involving preparing raw clay material, forming the blocks through extrusion or dry pressing, drying, firing in a kiln, and cooling. Defects and advantages of clay blocks are also noted. The document proposes using clay blocks as a filler material between reinforcement in concrete slabs, listing considerations for suitable filler materials. Installation details and cost savings compared to solid concrete slabs are provided.

Uploaded by

Nidhi Mehta
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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CLAY BLOCK

IVth SEM
CONTENT
 INTRODUCTION
 COMPOSITION OF CLAY BLOCK
 PROPERTIES
 PROCESS OF MANUFACTURING
 DEFFECTS
 ADVANTAGES
 INTRODUCTION TO FILLER MATERIAL
(CLAY BLOCK)
 INSTALLATION OF FILLER MATERIAL
 ADVANTAGES
 COST SAVINGS
INTRODUCTION TO CLAY BLOCKS

 Structural clay block describes a category of


burned-clay building materials used to construct
roofing, walls, and flooring for structural and non-
structural purposes, especially in fireproofing
applications.
 The material is an extruded
clay shape with substantial
depth that allows it to be laid
in the same manner as other
clay or concrete masonry.
COMPOSITION OF CLAY BLOCKS

  Composition of Clay →
SiO2+Al2O3+Impurities (CaO).

 Clay is cohesive so can be shaped when wet.


PROPERTIES
 Properties of brick are affected by composition of the
raw materials and the manufacturing processes.
 The properties that most concern the users of 
brick are :
1) durability,
2) colour,
3) texture, 
4) size variation,
5) compressive strength and
6) absorption.
PROCESS OF MANUFACTURING
 Clay bricks are made after a series
of manufacturing processes.
 Preparation of Raw Material (excavated ground).

 Pugging : Forming or shaping (mixing with water to


a plastic condition to obtain the desired shape).
 Stiff-mud, Soft- mud, Dry press processes.
 Setting and drying.
 Stiff-Mud Process (Extrusion)-The clay is mixed with just
enough water to produce plasticity .
 The clay is extruded through a "die" producing a horizontal
column of clay which passes through an automatic cutter.
 Cutter-wire spaces and die sizes should be precisely calculated to
compensate for shrinkage during drying and firing.
 As the clay column leaves the die, textures or surface coatings
may be applied
 The bricks are then stacked with care to allow sufficient
airspace between them to create even colouring and
uniform strength during drying and firing
 Extrusion Process -

1. Extrusion Die :  The die itself is a steel disk


(normally H13) with an opening, the size and
shape of the intended cross-section of the
final extruded product, cut through it.
2. Brick column left the die
3. Bricks are cut with wires .
 Dry-Press Process - This process is adaptable
for clays of very low plasticity.
 Instead of wooden molds, the clay is formed
with steel molds and is put under high pressure
to create a very compact, dense brick.
 Drying after moulding the brick unit through
either extrusion or soft mud process, bricks go
through the setting and drying stage. Before they enter the
kiln to be fired,(40-200 C at 24-48 hrs).
 The moisture must be minimized to prevent
certain defects and shrinkage from happening when
fired at extreme heat in the kiln.
 Shrinkage can cause the bricks to crack.
 Firing or burning - in kilns above 950C
Firing/Burning The fusibility of clay causes
it to become hard, solid and of relatively
low absorption when properly fired.

 Cooling – Cooling is done after the temperature has


reached the maximum and is maintained for a
prescribed time.
- 48 to 72 hr are required for proper cooling in
periodic kilns but in tunnel kilns, the cooling
period seldom exceeds 48 hr.
- Rate of cooling affects brittleness, colour
and shape.
 Following are the different types of
defects generally found in bricks:

 Over burning of bricks.


 Under burning of bricks.
 Bloating of bricks.
 Black core.
 Efflorescence.
 Brick cracking.
 Brick spalling.
 Chuffs.
ADVANTAGES
 Advantages:
1. Zero maintenance cost,
2. fire resistant,
3. energy-efficient,
4. sound insulating ,
5. allow flexible planning and construction
works,
6. and are ecological and sustainable.
CLAY BLOCK AS A FILLER MATERIAL
(ROOF)
 Filler slab roofs are solid reinforced concrete slabs with
filler material in the tension zone. The filler material
could be cheaper and/or lighter.
 A number of alternative materials can be thought of:
(a) brick or brick panel, (b) Mangalore tile, (c)
stabilized mud block, (d) Concrete Waste etc. Figure
9.2 below shows ceiling of a typical filler slab roof
using SMB filler.
 Depending on thickness of slab the tension zone of the
slab can be replaced by filler material
 The following points to be kept in mind for filler material
selection:

 Filler material should be inert in nature. It should not react with concrete
or steel in RCC slab constructed.
 Filler materials water absorption should be checked for as it will soak the
hydration water from concrete.
 Filler material should be light in weight, so that overall weight of the slab
reduces and also the dead load onto the foundations is reduced.
 Filler material should be low cost . This is very important to achieve
economy.
 Filler material should be of a size and cross-section, which can be
accommodated within the spacing of the reinforcement and also
thickness wise could be accommodated within the cross section of the
slab.
 Moreover the Filler slab also provides insulation (compared to a
conventional RCC slab) from the hot climate outside the building,
providing thermal comfort to the user. 
 Filler material texture should match with the desired ceiling finish
requirements so as not to provide an ugly ceiling pattern.
INSTALLATION OF FILLER MATERIALIN
SLAB

 Size of the filler material will be very crucial.


 It is must to decide the filler material before the
slab is designed.
 The dimension of filler material will help decide
the spacing of reinforcement and accordingly the
depth of the slab and other structural details will
be worked out.
ADVANTAGES
COST SAVINGS

 The table below shows the consumption of materials and cost


savings for 1 m3 quantity of the slab:

 Therefore installing of clay block as a filler material is proved to be


more economical .
THANK YOU

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