Construction and

Industrial Materials
Reported by:
Brannon Eludo
Jerammy Flores
 Building construction materials:
 Bricks
 Cement
 Mortar

 Concrete
 Lubricating Materials

 Materials for protective coating

 Packing Materials

 Belting Materials
 Adhesive
 Abrasive
A brick is a type of
construction material used to
build walls, pavements and Bricks
other elements in masonry
construction. Properly, the
term brick denotes a unit
primarily composed of clay,
but is now also used
informally to denote units
made of other materials or
other chemically cured
construction blocks.
The manufacture of bricks involves the following steps:

Preparations of clay
Essentially, brick are produced by mixing ground clay with water, forming
the clay into the desired shape, and drying and firing. In ancient times, all
molding was performed by hand. The site selected for the construction of
bricks must have suitable soil available in sufficient quantity; otherwise
unnecessary labour and cost of digging and transportation of the soil
would be involved.
A pugmill pug mill, or
commonly just pug, is a Pug Mill
machine in which clay or other
materials are extruded in a
plastic state or a similar
machine for the trituration of
ore. Industrial applications are
found in pottery, bricks,
cement and some parts of the
concrete and asphalt mixing
processes.
 Types of Molding

Hand molding - Whatever the force required for ramming and compressing of molding
sand, if it is obtained from a human hand, then it is called as hand molding. Hand molding
usually adopted in India which consist of two types; ground and table molding.

Ground molding Table molding

Types of Molding
Machine molding – this type of molding method is quite useful when large numbers of bricks
have to be manufactured quickly. Molding machines form thermoplastic resin, thermoset polymers, or
metal injection molding compounds into finished shapes. Injection molding machines consist of a barrel
and reciprocating screw assembly, an injection nozzle, and a hydraulic motor that feeds the molten
plastic or metal mix into a mold.
The manufacture of bricks involves the
following steps:
Drying of
bricks
Natural drying - It is also called hack drying, which comprises placing molded bricks in
rows on their edges, slightly above the ground called a hack. These bricks are air and sun-
dried that is strong enough to use for the construction of small structures.
Artificial drying - Temperature maintained by driers is usually less than 120 degree
Celsius and the process of drying bricks takes about 1 to 3 days. The bricks in stacks
should be arranged in such a way that sufficient air space is left between them for free
circulation of air.
The manufacture of bricks involves the
following steps:
Burning of
bricks
Burning is the last stage of brick making which usually imparts
hardness and strength to the bricks. The burning of bricks should be
done properly. The brick should not be over burnt as well as under
burnt. In general, bricks are burnt either in kilns or clamps.
Clamp burning – bricks and fuel are placed in
alternate layers. The lowermost layer contains more
fuel and the quantity of fuel is subsequently reduced
in the upper portions. Each brick tier consists of 4 to
5 layers of raw bricks.
 Qualities of Good Bricks
Size and shapes
Colour
Structure
Soundness
Hardness
Porosity
Strength
Resistance to fire
Durability
Efflorescene
 Cement
Cement is seldom used on its own, but rather to bind sand and gravel
together. May be prescribed as a material with adhesive and cohesive properties
which make it capable of bonding material fragments into a compact whole.
Cement are classified into two types; Natural cement and Artificial cement.
Natural cement and Artificial Cement

Natural cement - It is manufactured from stone containing 20 to 40 per cent of clay, the
remainder being carbonate of lime mixed with carbonate with magnesia. The stone are first burnt
and then crushed. It posses a brown colour and sets rapidly when mix with water.

Artificial cement - Portland cement is the most common type of cement in general use
around the world as a basic ingredient of concrete, mortar, stucco, and non-specialty grout. It is a
fine powder, produced by heating limestone and clay minerals in a kiln to form clinker, grinding
the clinker, and adding 2 to 3 percent of gypsum.
Chemical composition of cement
Uses of Cement

 It is used in cement mortar for masonry, plastering, pointing, etc.

 It is used for making joints for pipes, drains, etc.
 It is used in concrete for laying floors roofs and constructing lintels, beams, stairs, pillars.
 It is employed for manufacturing precast pipes, piles, fencing post.
 It is used in the construction of important engineering structures such as bridges, culverts,
dams, tunnels, light houses etc.
Manufacturing of Portland Cement
There are four stages in the manufacture of Portland cement. First is crushing and grinding the
raw materials, next is blending the materials in the correct proportions, third process is burning
the prepared mix in a kiln, and fourth is grinding the burned product, known as clinker,
together with some 5 percent of gypsum (to control the time of set of the cement). The three
processes of manufacture are known as the wet, dry, and semidry processes and are so termed
when the raw materials are ground wet and fed to the kiln as a slurry, ground dry and fed as a
dry powder, or ground dry and then moistened to form nodules that are fed to the kiln.
Rotary Kiln - is a physically large
process unit used in cement production
where limestone is decomposed into
calcium oxide which forms the basis of
cement clinker particles under high
temperatures. A rotary kiln is a pyro
processing device used to raise materials
to a high temperature in a continuous
process.
Testing of Portland Cement
Testing of ordinary Portland cement are carried out:

Chemical Composition Fineness Test

Consistency Test Setting Time Test

Soundness Test Tensile Strength Test

Comprehensive Strength Test

 Chemical composition test
 this test determines the chemical composition of cement, including the amounts of various
compounds such as calcium, silica, alumina, and iron oxide. It ensures that the cement
meets the desired specifications and standards.
 Fineness test
 The object of conduction this test is to check the proper grinding of cements as finer
cements have quicker action with water and gain early strength. Finer the cement, more
surface area of the aggregates covered by it. The fineness test has two test methods:
 Sieve test - The sieve analysis determines the gradation (the distribution of aggregate particles, by
size, within a given sample) in order to determine compliance with design, production control
requirements, and verification specifications.
 Surface area test – this test is also known as specific surface area test. It is better that sieve test.
Specific surface is the total surface of all the particles of cement per unit weight. It can be
determined by air permeability method.
Consistency Test
 This test is to determine the percentage of water required for preparing cement pastes of
standard consistency for other test. This test is performed through the use of Vicat
apparatus.
 Vicat apparatus - a device for determining the normal consistency and time of setting of Portland
cements that consists of a rod weighing 300 grams, having a needle in each end, and supported in
a frame with a graduated scale to measure the distance to which the needle penetrates the cement.
Setting times test

 Setting tests are used to characterize how a particular cement paste sets. For construction
purposes, the initial set must not be too soon and the final set must not be too late.
Additionally, setting times can give some indication of whether or not a cement is
undergoing normal hydration.
Soundness test

 Soundness of cement may be determined by two methods, namely Le-Chatelier method

and autoclave method. In the soundness test a specimen of hardened cement paste is boiled
for a fixed time so that any tendency to expand is speeded up and can be detected.
Types of soundness test methods:
 The Le-Chatelier’s method
 The autoclaving method
Tensile strength test

Is a destructive test process that provides information about the tensile strength, yield strength,
and ductility of the metallic material. It measures the force required to break a composite or
plastic specimen and the extent to which the specimen stretches or elongates to that breaking
point.
Compressive test

 The test for compressive strength is generally carried out by crushing cubes of hardened
cement-sand mortar in a compression machine. The compressive strength of the cubes is
determined by the highest stress applied to a cube specimen that causes it to fracture.
 Mortar

Mortar - is a workable paste which hardens to bind

building blocks such as stones, bricks, and concrete
masonry units, to fill and seal the irregular gaps between
them, spread the weight of them evenly, and sometimes to
add decorative colors or patterns to masonry walls.

Ingredients of mortars are:

 Binding or cementing materials such as cement and
lime;
 Fine aggregates such as sand, surkhi, ashes, cinder etc.
 water
 Types of mortars

 Cement mortar – it is the strongest type of mortar and is therefore preferred for use in the
construction of structures subjected to heavy loading. The ratio of cement to sand is
usually 1:3 to 1:6 by weight for the mortar to be workable and strong.
 Lime mortar –It is one of the oldest known types of mortar, used in ancient Rome and
Greece, when it largely replaced the clay and gypsum mortars common to ancient
Egyptian construction. The usual preparation of lime mortar is 1:2 to 1:3 by volume.
 Lime-cement mortar - is also known as compo or gauged mortar. It is prepared by mixing
cement with lime mortar in suitable proportions. The process of adding cement which is
called gauging. Can make the lime mortar economical, strong and dense. The usual ratio
of lime-cement mortar are: 1:1:6 ; 1:2:9 and 1:3:12
 Concrete

Concrete is a composite material composed of aggregate bonded together with a fluid cement
that cures over time. It is a mixture of cement or lime, sand, bricks or stone ballast and water,
which when placed in forms and allowed to cure, it becomes hard like stone. Concrete is much
stronger in compression than tension. In order to enable it to resist tensile stresses it is
reinforced or strengthen with steel in a form of steel bars or wire netting etc. the concrete so
obtained is called ‘Reinforced Concrete’
 Types of concrete

Cement concrete – is compose of cement, sand and a coarse aggregate, mixed in suitable proportion
in addition to water.
Preparation: 1 part porthland cement: 1 ½ to 8 parts clean sand: 3 to 6 parts coarse
aggregate.
Lime concrete – is consists of lime, fine aggregate and a coarse aggregate, mixed in suitable
proportions in addition to water. It is cheaper and has less strength than cement concrete.
Preparation: 1 part lime: 2 to 3 parts sand: 3 to 4 parts aggregate.
Proportioning method

Proportioning refers to selection of the proper amount of ingredients to make a batch of

concrete. Selecting concrete proportions involves a balance between economy and
requirements for placeability, strength, durability, density, and appearance.
Arbitary method
Trial mixture method
Minimum voids method
Fineness modulus method
Lubricating materials

When one solid surface is moved to relative to another solid surface with which it is in contact,
there is a frictional resistance to motion. In lubrication, a lubricant performs the following
functions:
 It reduces the co-efficient of friction between two rubbing surfaces of machinery as result of
which the loss of energy due to friction is reduced.
 It does not allow the direct contact between the rubbing surfaces by keeping its own film in
between this rubbing surfaces. In this way, injuries due to seizure and wear are reduced.
 It acts as a coolant or heat transfer medium by removing the frictional heat generated by rubbing
of surfaces.
 Mineral lubricating oil

Mineral lubricants use base oils which

are obtained as a by-product from the
refining of crude oil. Synthetic oils are
created through further refining of
mineral oils or through synthetization
of chemical components.
Grease

Lubricating grease is a solid to semi-solid dispersion agent in liquid lubricant. Other

ingredients imparting special properties may be included. Grease are normally used under
conditions lubrication for which oil is not suitable as or convenient. Some uses of grease:
 High bearing loads
 Slow journal speed
 Temperature extreme
 Cleanliness or avoidance of splash or dip.
 Solid Lubricants

Solid lubricants are solid materials having strong

adherence to metals, very low shear strength, and
good elastic properties. These materials should be
stable at high temperature, chemically inert, and have
a high heat conductivity. They may be in the form of
powders, films or composite materials. They include
substances with layered structures such
as molybdenum disulfide and graphite.
Packing Materials

These materials are used for packing into joints or between surfaces of machine parts in
contact.
 Gasket

A Gasket is an elastomeric component that covers the

intersection between two surfaces. They are usually
manufactured from a variety of materials, including
rubber, cork or paper, metal, copper, and foam. This
flexible element can be used for a broad scope of
purposes due to its functionality.
 Glass wool

Glass wool is a thermal insulation material

consisting of intertwined and flexible glass fibers,
which causes it to "package" air, resulting in a low
density that can be varied through compression and
binder content. The process traps many small
pockets of air between the glass, and these small air
pockets result in high thermal insulation properties.
 Burlap

t is a material with a coarse texture, and that is

made from strong plant fibres. It’s mostly used in
weaving. Because of their strength, they are durable
and come in handy for all kinds of outdoor projects.
Moreover, and the reason it is a favorite for many is
the fact that it is heat resistant. And though it is
naturally beige, you can opt to dye it to any colour
you please.
 Asbetos

Asbestos is a mineral known for its resistance to heat,

electricity and corrosion. This led to its use in many
products, including insulation, construction materials,
brakes and more. Its fibers can be inhaled or ingested,
which contributes to the health risks associated with
asbestos exposure.
 Cork

Cork is an impermeable buoyant material. It is

the phellem layer of bark tissue which is
harvested for commercial use primarily from
Quercus suber, which is native to southwest
Europe and northwest Africa. Cork is
composed of suberin, a hydrophobic
substance.
 Adhesive
They are required for structural parts, such as bonding of concrete to concrete, ceramic
tiles to concrete, masonry, construction panels, outside doors, sealing metal parts into
concrete, civil engineering, composite bonding (FRP panels), metal bonding, structural
glass.
 The two types of adhesives used in construction are:

Non-structural adhesives are used to bond decorative materials, such as floor and
wall coverings, and other materials which do not need very high strength (panels,
fibers and particle boards, trim, some interior doors). These adhesives may be
emulsion or dispersion adhesives, neoprene contact adhesives, solvent-based
adhesives, natural and renewable adhesives and glues.

Structural adhesives give at least 5 to 8 MPa tensile shear strength. They are
required for structural parts, such as bonding of concrete to concrete, ceramic tiles
to concrete, masonry, construction panels, outside doors, sealing metal parts into
concrete, civil engineering, composite bonding (FRP panels), metal bonding,
structural glass. These adhesives may be epoxy adhesives, structural polyurethanes,
silicones and structural acrylics.
 Abrasive

An abrasive is a material, often a mineral, that

is used to shape or finish a workpiece through
rubbing which leads to part of the workpiece
being worn away by friction.
 Materials for Protective Coating
Protective coatings are a simple way to reduce corrosion, by limiting the exposure of the metal to a
corrosive environment. Paint is a very common protective coating, but tar, pitch, bitumen and plastics are
also used.
 What are Protective Coatings Used For?
These are some of the most common uses of protective coatings:
1. Corrosion Prevention
One of the biggest threats to the lifespan of metals is corrosion. What makes it worse is that corrosion
doesn’t just start and end in a day. It happens over time, degrading the metal, and causing it to fail when
you least expect it. And when the metal fails, the effects could be catastrophic, depending on where the
metals are used. Therefore, we have to protect the metals from corroding, so we can extend the lifespans.
2. Chemical Protection
Some surfaces get to come in contact with chemicals during their lifetime. For instance, the walls of a
chemical factory need protection, and so does the interior lining of tanks that carry chemicals. Otherwise,
the chemicals could destroy these surfaces. And this is where protective coatings wade in to save the day.
Weather Protection
The weather can be one of the biggest issues of structures that are exposed to it. The reason
for this is that it is unpredictable, persistent, and unforgiving. As a result, the weather could
easily wear some surfaces out over time, and make them lose their integrity.

4. Hygiene
This is another important use of protective coatings. Some coatings won’t bow to influence
from the microorganisms in the environment. Such coatings are often used in hospitals and
laboratories to discourage the growth of bacteria and other organisms, such as mold and
mildew. As a result, the rooms where they are used see lesser exposure to contamination by
these microorganisms.
Types of protective coating

Metallic coating - A metallic coating consists of a protective layer that is corrosion resistant
and can defend the surface against severe environmental conditions by modifying the
properties of the material's surface. Various methods are used to apply metallic coatings to a
surface.
 Example of metallic coating is:

Spraying - Thermal spraying is the term given to a

coating process that involves materials being used in a
molten or semi-molten state to coat a surface. The
materials used can be either metallic or non-metallic and
in the case of metallic materials, this is also known as
metal spray coating.
2 Types of protective coating

Non-Metallic Coating - Common types of such coatings are plastic or rubber coating. This
involves application of a layer of the given polymer onto a substrate material.
Example of non-metallic coating:

Anodized coatings - Anodizing is an electrochemical process that converts the metal surface
into a decorative, durable, corrosion-resistant, anodic oxide finish. Aluminum is ideally suited
to anodizing, although other nonferrous metals, such as magnesium and titanium, also can be
anodized.
Vitreous or porcelain enamales - is made by fusing powdered glass to a metal substrate by
firing, resulting in decorative and functional surfaces. The enamel powder melts, flows, and
then hardens to a smooth, durable coating. Frits are the basis and main component of an
enamel coating.
Chemical dip coatings - a process by which substrate material is submerged in conformal
coating, then taken out and allowed to drip dry. Once the excess coating has drained, the
substrate material is further dried using one of a variety of techniques, often baking
THE
END?