What is red brick made of? What and how is brick made from?

Knowing what brick is made from, what it comes in, how it differs, and what one or another type of brick is intended for will allow you to consciously and correctly select the main material for any construction at the stage of pre-design decisions.

On household level There are two varieties - red (ceramic brick) and white (sand-lime brick), which, despite the similarity of shape and purpose, differ significantly in source materials, manufacturing technology and use. It seems more reasonable to divide into the following varieties, differing in the method of production:

Fired brick, or ceramic, produced by sintering the powdered components of a brick blank into a stone-strength material.
Unfired (pressed) brick, obtained by turning special mixtures into a stone-like material due to the hydration of a binder (usually based on Portland cement), without the use of firing. This also includes sand-lime brick, obtained by autoclaving a mixture of lime and sand.

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The main substance that makes up ceramic bricks is ordinary clay - a mineral mass that acquires plasticity when water is added, retains its shape after drying and hardens to a stone state when fired. Clay is widespread, but even in one deposit its characteristics can vary depending on the depth of the layers. The basis of clay raw materials, as a rule, is 4 minerals: kaolinite, illite, montmorillonite and quartz. Properties of clay taken into account when making bricks:

Plasticity is the ability to change shape under the influence of force without breaking and maintain it after the action ceases. There are high-, medium-, moderate- and low-plasticity, as well as non-plastic clays.
Bonding ability - maintaining plasticity when adding non-plastic inclusions. It is measured by the ability to bind the amount of sand expressed as a percentage (from 20 to 80) to its own weight.
Air and fire shrinkage - changes in the size of samples during drying and firing, respectively.
Caking is the property of hardening to a stone-like state when heated. Clays with a sintering temperature of up to 1100°C are considered low-temperature, in the range from 1100 to 1300°C - medium-temperature; over 1300°C - high temperature.

Fire resistance - the ability not to melt when heated. Pure, highly plastic kaolinite clays used for the production of porcelain have high fire resistance (not lower than 1580°C). Refractory clays are those used for making sewer pipes and facing bricks with a small amount of impurities and fire resistance from 1350 to 1580°C. Low-melting clays are considered to be heterogeneous in composition with a fire resistance below 1350°C, used for the production of bricks, blocks and tiles. The degree of suitability of clay for the manufacture of specific products depends on its mineral, chemical and granulometric composition.

Regulating additives

To give the finished product the required properties, the following types of additives are added to the clay:

emaciated - inorganic substances, facilitating the molding of the mass and reducing shrinkage: sand, ash, slag;
burnable - organic inclusions that reduce density and increase porosity: sawdust, powdered coal and peat;
special - regulating the firing temperature of iron-containing ores and sandstone, facilitating the molding of ulphite-alcohol stillage, metal oxides coloring the finished brick in the desired color.

Raw material processing stages

Before you become finished products, the clay that is part of red brick necessarily goes through the following stages:

extraction and preparation;
molding and drying;
burning.

Typically, clay extracted from a quarry is transported to the processing site, where primary grinding and rough cleaning of foreign inclusions take place. Then drying, final grinding, sifting and the necessary moisture for subsequent pressing are carried out to 9-12%. The molding press gives the powder the required shape, after which the raw material is fed into the drying chamber, where due to a gradual increase in temperature, water evaporates evenly and does not disturb the texture of the brick surface.

Firing, consisting of heating, firing itself and cooling, takes place in a special furnace, where the prepared raw materials are fed by a conveyor.

Thus, the clay is transformed into a building material with the necessary properties - bricks.

In addition to clay, the main raw material for the manufacture of ceramic bricks and wall blocks can be industrial waste generated during the enrichment of coal, as well as during the combustion of thermal power plant fuel, ash, consisting mainly of aluminosilicate glass, clayey matter and quartz. The difficulty of using such raw materials lies in the instability of its properties.

What are unfired bricks made from?

Today at economic activity A variety of materials are widely used - bricks and blocks produced using the following non-firing technologies:

autoclave hardening of lime-sand mixture;
hyperpressing a mixture of crushed limestone rocks with water and cement.

Regardless of the type of raw material, they are united by the lack of high-temperature processing of brick blanks.

Sand-lime brick

A common example of a material obtained by autoclave hardening of a lime-sand mixture is white sand-lime brick. The primary composition of sand-lime brick includes approximately 9 parts of quartz sand and 1 part of lime. Wetting the mixture with water initiates the reaction of quenching the lime component, resulting in the formation of a plastic mass from which brick blanks are formed, subjected to autoclaving - steam treatment at a temperature of 170-200 ° C and a pressure of 8-12 atm. Sometimes dyes and substances are added to the mixture to make the brick more resistant to weathering.

Mixture components

Sand is a natural or artificial (industrial waste) loose mass of homogeneous small, from 0.1 to 5 mm, grains from various minerals. The quality of the sand included in the brick determines the quality finished product and features of production technology. The geometric shape and surface texture of the sand grains are important for the ease of shaping the raw mixture the desired shape and the intensity of interaction with lime when heated in an autoclave. Sharp-angled mountain sands, unlike smooth river sands, adhere better to lime. Quarry sand must first be cleared of foreign inclusions.

The next component is lime, obtained by crushing to a size of 40-100 mm and subsequent firing at a temperature of 1100-1200 ° C of rocks containing at least 90% calcium carbonate - chalk, limestone, calcareous tuff and marble. Under the influence of temperature, limestone breaks down into carbon dioxide and lime. At all stages of sand-lime brick production, water from artesian wells is used.

Also in brick production, lime-slag and lime-ash mixtures are used with complete or partial replacement of sand with silica-containing ones industrial waste- ashes from thermal power plants and slags. Made from waste and ordinary sand-lime brick are identical in quality.

Brick produced by hyperpressing

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The starting material for unfired bricks are mixtures consisting of Portland cement or lime as a binder, various mineral fillers (sand, crushed shell rock), water and inorganic dyes. In non-firing technologies, water, hydrating the components of hydraulic binders, is necessary to artificially create a stone-like structure, which is why the disadvantage of such bricks is their low heat resistance. When critical values are reached, usually above 300°C, the chemical liberation reaction starts bound water, because of which the brick quickly loses strength.

Features of the technology

At the stages of preparing raw materials and forming blanks, non-firing technology resembles the production of concrete blocks, however, the source material of such bricks includes a filler compacted by pressing - crushed shell rock, stone processing waste, etc. Since water is consumed only for hydration of cement, a significantly smaller amount is required. The final shape is given by hyper-pressing - strong, up to several tons per 1 square meter. cm, compressing the mixture into special form, after which the products are stored or sent for steaming in order to speed up the process of acquiring the required strength.

The simplicity of the technology, due to the absence of expensive high-temperature stages, made it possible to make it widespread, often to the detriment of the quality of the finished product.

These are the main materials and technologies used for the manufacture of a variety of bricks, blocks and facing materials used in residential and industrial construction.

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Brick is artificial stone, manufactured in different ways from clay, sand, lime, cement with the addition of various pigments. Depending on the source material, as well as on the production technology, there are several types of bricks.

The most popular are clinker, decorative, ceramic, silicate, refractory, and facing bricks.

Types of bricks

Ceramic brick is the same classic red stone made from baked clay. This durable and versatile type of brick is widely used in construction, and modern technologies allow you to get away from the red color and get a stone of any other shade. Ceramic bricks can be hollow or hollow, which affects both the characteristics of the stone and its cost.

Sand-lime brick is an artificial stone originally white, made by autoclave synthesis from lime and sand. During the production process, the stone can be pigmented. Sand-lime brick differs from ceramic brick in its improved soundproofing characteristics.

At the same time, such bricks are not very resistant to moisture, so the scope of their use in construction is limited.

Refractory bricks are made from fired clay, called fireclay, with the addition of coke or graphite to give the stone greater strength. Such bricks can be carbon, quartz, alumina and lime-magnesia. Chimneys are made from refractory bricks, fireplaces and stoves are built.

Facing bricks are made from cement, with the addition of limestone and pigments. This material is strong, durable, looks great and protects facades well from moisture and temperature changes.

When making facing bricks, pressing technology is used, and this stone is used for finishing facades, restoring destroyed structures, decorating sidewalks, building fences, and so on. Facing bricks do not accumulate dirt and retain their original appearance for decades.

How to choose a brick?

First of all, they focus on the purpose of the stone. Depending on where it is to be used, emphasis is placed on specific characteristics. Manufacturers use special markings to indicate the strength of bricks. The load is indicated by 1 square meter– M100, M200 and so on. The higher the number, the higher the stone’s resistance to deformation.

When choosing a brick, you must also take into account its porosity, frost resistance, density, and thermal conductivity. Density is the ratio of the volume and mass of a brick. Frost resistance is the number of freezing and thawing cycles during which the stone will retain its original strength.

To mark frost resistance, use the letter F and numbers. In residential construction, as a rule, bricks marked F35 are used.

The most popular technologies

If the brick is made by firing clay, then before this process the clay is laid out in a concrete pit and filled with water. After three or four days, the clay is taken out and mechanical processing begins - at the enterprise, stones are removed from the clay composition, thoroughly mixing the mass.

After this, the clay goes into a belt press, where the bricks are cut according to a standard pattern. In a special chamber, the bricks are dried under the influence of steam, and then sent to a tunnel kiln for firing. If the use of firing is not intended, then the brick is made by pressing.

Mineral components are welded under high pressure using binders and water. The finished substance is kept for up to five days, and after that it is mixed with cement in a concrete mixer. Bricks are then formed and allowed to rest for three to seven days.

There are many ways to improve the quality characteristics of bricks - add fireclay to the mixture, use vacuum pressing, tunnel dryers with recirculation.

It is believed that the highest quality brick is obtained by firing in kilns operating at liquid fuel or gas. Mineral supplements and pigments help to obtain the desired color. In order to improve the visual characteristics of the brick, its surface is subject to decorative treatment.

Brick, as the oldest building material, is found almost everywhere; it is universal, beautiful, and durable. Let's try to understand in detail what types of bricks there are, depending on the material of its manufacture, the scope of its application, manufacturing methods and sizes. Its format and composition can be varied, this material has come a hard way throughout the history of civilization.

Brick: brief information about the material

Brick is made from clay. Depending on the type of clay and production method, there are several types of bricks (ceramic, silicate and refractory), which in turn are also divided into subgroups. The most extensive classification of bricks in construction and landscape design of a site consists of 2 types: building bricks and facing bricks.

Construction bricks are used for laying walls and piers. It is, as a rule, cheaper and GOST standards are not so demanding for it. The surface of building bricks can be chipped, rough, stained by salt protrusions and vary in color. After laying the building brick, it is additionally necessary to veneer it, plaster it and paint it to taste.

For facing bricks, GOST requirements are an order of magnitude higher: the material must be uniform, without noticeable color changes, without chips, cracks or irregularities. The facing brick can be shaped, which is what determines its shape - slightly rounded, angular, non-standard shape, etc.

Also, brick, regardless of the type of clay and purpose, can be solid, effective and super-effective, we will also talk about this.

There is a special form of brick - with a chamfer, when the corners of the building material are made beveled. This innovation not only improves the appearance of the brick, but also reduces damage during transportation.

When choosing a brick, special attention is paid to its physical properties: strength, frost resistance, moisture absorption. We will definitely talk about this below.

You should also pay attention to one of the most important components appearance brickwork and structural strength - this is the technology for creating seams, because. Too large/small seam sizes will not only spoil the “face” of the structure, but will also make it less stable.

Varieties

As you know, building bricks vary in size, characteristics and purpose. In this case, this material can be divided into 3 categories: One-and-a-half. Single. Double. The size of a standard brick is different for each of these types. It is determined by three parameters: length, width and height. The size of the brick (standard single type), which is used in the construction of most modern buildings and institutions, is as follows: 250x125x65 millimeters.

In this case, the silicate (double) material has dimensions of 250x120x188 millimeters. In construction, the size of a standard brick is 250x125x65 millimeters. That is, the most used type of brick is single. In addition, in the construction industry its thickened version is often used, with a length of 250 mm, a width of 120 and a height of 80 millimeters. It is also worth noting the modular varieties. The dimensions of a single modular brick are 138x13x288 millimeters.

It is worth noting that so-called ceramic stones can also be used in the construction of walls. They have nothing to do with stones, and therefore in production they are labeled as ceramic blocks. Many sellers also refer to them as “double brick,” so when purchasing, do not assume that this is a different type of material. Ceramic stone, block and double brick are one and the same product. And its dimensions are as follows: 250x125x138 millimeters (length*width*height, respectively).

What is sand-lime brick made of?

White sand-lime brick is the most popular and inexpensive building material. It contains only environmentally friendly substances. Approximately ninety percent sand-lime brick consists of purified quartz sand, and ten percent water and lime. Depending on the method of its production, the percentage may vary.

Typically, sand that is used to make bricks undergoes very careful processing. It is cleaned of all kinds of clay and organic impurities, since impurities reduce the strength of the product. Lime, which is part of the sand-lime brick, must also have a certain chemical composition. For example, the MgO content in lime cannot contain more than five percent. Ground bricks are usually used to create bricks.

Composition of red brick

Red brick has long been recognized as the most reliable and versatile building material. This natural material is created from clay. Depending on the iron content in it, the color of the brick changes. Red bricks are usually made from red-burning clay. If the clay is white-burning, then the brick will acquire an apricot tint. Often certain pigment additives are added to the brick composition.

To obtain high-quality red brick, homogeneous clay is used, which is mined in a fine fraction. The quality of the resulting product depends on the correctly selected components.

What are ceramic bricks made from?

Ceramic or building bricks are actively used for the construction of load-bearing wall structures and interior partitions. High-quality bricks must be made from a constant composition and clay of fine fractions. In the process of proper firing of clay, its refractory elements dissolve. If you follow the correct technology for molding and drying the raw materials, you will get the most durable ceramic brick.

Depending on the components, the brick can be light yellow or dark brown. Nowadays, pigmentation of ceramic bricks is often used to give it certain shades.

Brick size standard

There are single, double and one-and-a-half bricks; we will consider the sizes of each type below.

In the process of development of the construction craft, certain standards have been developed that the material must meet. Single brick size: 120mm wide, 250mm long and 65mm high. It is this size of bricks that is considered ideal for masonry with alternating longitudinal and transverse placement.

Over time and the development of construction, more and more diverse materials were required. This is how new, non-standard one-and-a-half-size bricks appeared. Their parameters are: 120 mm wide, 250 mm long and 88 mm high.

The use of such bricks requires knowledge of a special masonry technique designed to lighten the final weight of the building. So, it is necessary to alternate solid bricks with porous, perforated or hollow ones.

Double brick has impressive dimensions, as a result of which it is never made solid. The brick size is 120 mm wide, 250 mm long and 103 mm high. They are used only for lightweight masonry.

White brick: sizes and applications

White or sand-lime brick is made on the basis of silicate, which is why it got its name. Durable and lightweight material, which is mainly used for the construction of walls and partitions. Such bricks are never used for laying foundations, stoves, pipes, fireplaces or plinths. Standard size of white brick: 250x120x88 mm.

Compliance with GOST GOST

(State standards) do not apply to products of this type in Russia, especially for new ones technical products, which appeared on the market several years ago. Of course, the use of ceramic bricks in the construction of a residential building or other buildings is very profitable, because due to large sizes the costs of its laying are minimal. Accordingly, the speed of work is many times greater than the time required for laying single material. In addition, the savings also apply to the cement mortar that needs to be prepared for laying a row of bricks.
Ceramic stone is mainly used in the construction of multi-story buildings, be it a residential building or a garage. Statistics show that the number of one-story houses in which this type of material is used during construction is only a few. Although even if we compare the total number of multi-storey institutions with walls made of ceramic stone and the same buildings with classic single brick, the difference will be several dozen times.

Types of bricks and their sizes

When starting to search for a suitable material for cladding or building walls, you should pay attention to special attention to standards for product edges. This will help you correctly calculate the masonry pitch and select the quantity you need.

There are the following 3 standard brick sizes:

European standards have the following standard sizes:

DF-240x115x52 mm;

2 DF-240x115x113 mm;

NF-240x115x71 mm;

RF-240x115x61 mm;

WDF-210x100x65 mm;

Physical properties of bricks

Strength

The strength of the brick directly affects the stability and durability of the structure. The strength is determined based on the marking of the brick, which is established by the manufacturer using experimental methods - the compressive strength of the material (how many kg will 1 cm2 of material withstand).

It is customary to mark bricks as follows: the letter “M” and the number after it indicate what load the material can withstand: M100, M125, M200, M300, etc.

For laying the walls of one- and two-story buildings, it is allowed to use M100 brick
For laying the walls of high-rise buildings, bricks with a strength of at least M200 (preferably M300) are used.
The foundation must be laid with bricks M150 and higher

It should also be noted that the higher the strength of the brick, the less damage will be caused to it during transportation.

Frost resistance and moisture absorption

The frost resistance indicator determines how many cycles of sudden temperature changes in winter season can withstand the material. Frost resistance, like other physical properties of bricks, determines the durability of the material, and, accordingly, the entire structure.

Brick manufacturers use an experimental method to find an indicator of the frost resistance of a material: water-saturated brick is frozen and thawed until it begins to lose its strength properties. Bricks are marked for frost resistance as follows: put the letter “F” and next to it a number indicating how many cycles the brick can withstand and the higher the number, the better its frost resistance, and therefore its durability.

Moisture absorption of brick is also one of the most important physical properties material, which is interconnected with frost resistance - the lower the moisture absorption, the higher the frost resistance.

The following GOST standards for moisture absorption of the material have been established:

Sand-lime brick (or other material to which lime is added) – up to 20%
Brick made from white-burning clays – up to 6%

It should be noted that the frost resistance index for building bricks should be 15 cycles, and for facing bricks from 25 and above. The frost resistance of high-quality imported bricks can reach “50”, which is a very high indicator.

What you need to know

In terms of its strength characteristics, white sand-lime brick is better than red brick, but due to its poor moisture resistance, it is not suitable for underground masonry; it can be used for cladding the foundation, especially since such a building material has a very presentable appearance.

The only type of brick that can adequately replace red brick in underground work is clinker brick, made from special types of clay. This building material is much stronger and can withstand moisture. However, its high cost makes its use in creating foundations impractical.

Clinker brick belongs to the cladding grades and is used, as a rule, in the process of cladding work on building facades. It is strictly not recommended to use any brand of hollow brick for underground masonry. It perfectly absorbs moisture and is not able to withstand bending and compression loads. It is also not recommended to build a foundation using any brand of sand-lime brick, which is very poorly resistant to temperature changes and is easily destroyed by water, which is not surprising, given the fact that sand-lime brick is essentially pressed sand.

Brick weight

Another characteristic of a brick is its weight. For various types products, this indicator is completely different. Thus, the weight of standard ceramic or sand-lime brick is 3.8-4 kg. Moreover, if the brick has cavities inside, then it will weigh less. Therefore, during design, the weight of each brick is not taken into account, but only the specific masonry, that is, the weight of 1 cubic meter building material plus the weight of the required amount of cement mortar.

The specific gravity of masonry can vary from 600 kg/m³ to 1800 kg/m³ and directly depends on the weight of each brick. By calculating the weight of the future building at the design stage, you can make adjustments to laying the foundation, thus making the structure stronger and more reliable.

Few people know, but unified brick standards in Russia were introduced only a few years ago - in 2008. And this despite the fact that it first began to be used in 1927. To everyone's surprise, Soviet times Almost all buildings were created using bricks that did not meet any standards and requirements. However, it is precisely such buildings at the moment are the most durable and wear-resistant.

Making bricks using artisanal methods. DIY brick

Source: building-ooo.ru

Brick of any kind in all reference books and dictionaries is defined as an artificial stone in the shape of a bar. There are several types of this building material, depending on what the bricks are made from and what production method is used.

Based on these characteristics, two main groups can be distinguished:

Ceramic

This is a classic red brick made of baked clay or a mixture of several types of it.

Silicate

Made in an autoclave from sand and lime, the color depends on the additives. White brick can be given any color, incl. red, but this will not give it the right to be called red - it will remain silicate red.

Types and quality of bricks

The scope of application of this material is very wide. Red brick is used to build load-bearing and self-supporting walls and partitions in buildings of various heights; it is used to fill voids in concrete structures, lay foundations, internal parts of furnaces, etc.

Building brick is called ordinary brick, but its front (facing) appearance is more valued. After firing at high temperature the material is durable and beautiful, and is widely used for cladding the external walls of buildings and plinths, restoration work and for interior design.

Properties of ceramic bricks:

Strength and durability.
Frost and moisture resistance.
Reliable sound insulation.
Hydrophobic and quick drying.
Environmental friendliness. The natural composition of bricks and time-tested technology guarantee the safe stay of people in brick walls.
High density (with manual molding reaches 2000 kg/m³).

The disadvantages include high cost, which is explained by the complexity of the technology. This material is very durable; houses made from it last hundreds of years. If you want to build a quality building, you should not try to make bricks yourself – It is impossible to ensure a sufficient firing temperature in artisanal conditions.

For cladding, you should buy material from the same batch, otherwise the color may differ.

Types of fired bricks

Private requires plastering. Often, a pressed pattern is made on its side for adhesion to the solution.
The front has two smooth surfaces; they also produce textured and shaped types. There are many voids inside to increase thermal insulation.
Kiln and fireclay are made from refractory clay. The material is sand-colored and grainy.

When buying a brick, it is important to understand its purpose. Ordinary brick is much cheaper than face brick and there is no point in overpaying for the construction of walls.

Basic composition and properties of clay

The useful properties of the material directly depend on what the brick is made of and how accurately the technology is followed. A high-quality product can be obtained by supplying clay with a constant composition and uniform production operation.

The facial variety is made from fine clay. There are few rich deposits with a uniform mineral composition left. In most cases, mining is complicated by multi-layers of clays of different compositions. The layers are cut off with an excavator, the clay is crushed and mixed until an average composition is obtained. This is necessary for uniform drying and firing, since clay of different composition requires individual thermal and time processing conditions.

Typically, an enterprise works with raw materials from one deposit, so the right technology allows for many years receive a quality product. When exploring and developing new deposits, the quality and quantity of clay is analyzed. The best red brick is obtained if the clay composition does not require additives. Typically, clay is suitable and cannot be used to produce other ceramic products.

When water is added, the mineral mass becomes plastic, and after drying it retains its shape. After firing, the clay hardens and becomes very durable.

For the production of red brick, raw materials are suitable, which include:

Kaolinite
Illit
Montmorillonite
Quartz

Important properties of clay for making bricks:

Plastic. The clay should not collapse when kneading and retain its shape. Plasticity can be high, medium, moderate and low. Non-plastic clays are also found.
Bonding ability. The raw material retains its plasticity after adding additives. It varies as a percentage of the amount of sand and can be in the range from 20 to 80%.
Shrinkage. Changes in size after drying and during firing.
Caking ability. The property of hardening when heated. Low-temperature clay is sintered at temperatures up to 1100 ° C, medium-temperature clay - 1100-1300 ° C, high-temperature clay - more than 1300 ° C.
Fire resistance. When heated, the raw material should not melt. The highest fire resistance is found in pure, highly plastic kaolinite clays, from which porcelain is made. The facing type is made from refractory raw materials with a small amount impurities. For ordinary bricks, a fusible type is sufficient.

Supplements

It is impossible to achieve without additives high quality material. The technologist who compiles the recipe and knows how to make brick according to GOST, provides ways to improve the quality of the raw material.

The following additives are used:

Slag, sand, ash.

Added to thin the raw material, facilitate formation and reduce shrinkage.

Sawdust, coal and peat powder

Organics are added to reduce density. After the additives burn out, they leave pores.

Iron ore, sandstone

Special additives for regulating the firing temperature.

Ulphite-alcohol stillage

Makes molding easier.

Metal oxides

Gives color.

The technologist’s task is to select the optimal composition of raw materials, molding, drying and firing modes.

Color

You can achieve the desired color not only with the help of additives. In most cases it all depends on mineral composition clay, which is redder after firing. This type of clay is called red-burning clay.

Quite rarely, white, yellow and apricot-colored ceramic bricks are made from white-burning clay.

The brown color is obtained after adding pigments.