Joseph Burton and William Burton

“ Under the action of the high-pressure steam the lime attacks the particles of sand, and a chemical compound of water, lime and silica is produced which forms a strong bond between the larger particles of sand. This bond of hydrated calcium silicate is evidently different from, and of better type than, the filling of calcium carbonate produced in the mortar-brick, and the sand-lime brick is consequently much stronger than the ordinary mortar-brick, however the latter may be made. The sand-lime brick is simple in manufacture, and with reasonable care is of constant quality. ”

“ In the 16th century bricks were increasingly used, but down to the Great Fire of London, in 1666, the smaller buildings, shops and dwelling-houses, were constructed of timber framework filled in with lath and plaster. In the rebuilding of London after the fire, bricks were largely used, and from the end of the 17th century to the present day they have been almost exclusively used in all ordinary buildings throughout the country, except in those districts where building stone is plentiful and good brick-clay is not readily procurable. ”

“ Blue Brick is a very strong vitreous brick of dark, slaty-blue colour, used in engineering works where great strength or impermeability is desirable. These bricks are made of clay containing front 7 to 10% of oxide of iron, and their manufacture is carried out in the ordinary way until the later stages of the firing process, when they are subjected to the strongly reducing action of a smoky atmosphere, which is produced by throwing small bituminous coal upon the fire-mouths and damping down the admission of air. ”

“ Shales are sometimes passed through a grinding-mill before they are exposed to the action of the weather, as the disintegration of the hard lumps of shale greatly accelerates the “weathering.” In the case of ordinary brick-clay, in the plastic condition, grinding-mills are only used when pebbles more than a quarter of an inch in diameter are present, as otherwise the clay may be passed directly through the pug-mill, a process which may be repeated if necessary. ”

“ The presence of magnesium salts is also very objectionable, as these generally remain in the burnt brick as magnesium sulphate, which gives rise to an efflorescence of fine white crystals after the bricks are built into position. Clays which are strong or plastic are known as “fat” clays, and they always contain a high percentage of true “clay substance,” and, consequently, a low percentage of sand. Such clays take up a considerable amount of water in “tempering”; they dry slowly, shrink greatly, and so become liable to lose their shape and develop cracks in drying and firing. ”

“ These ordinary brick clays vary considerably in composition, and many clays, as they are found in nature, are unsuitable for brickmaking without the addition of some other kind of clay or sand. The strongest brick clays, i.e. those possessing the greatest plasticity and tensile strength, are usually those which contain the highest percentage of the hydrated aluminium silicates, although the exact relation of plasticity to chemical composition has not yet been determined. ”

“ The machine-made plastic bricks are made of tempered clay, but generally the tempering and working of the clay are effected by the use of machinery, especially when the harder clays and shales are used. The machines used in the preparation of such clays are grinding-mills and pug-mills. The grinding-mills are either a series of rollers with graduated spaces between, through which the clay or shale is passed, or are of the ordinary “mortar pan” type, having a solid or perforated iron bottom on which the clay or shale is crushed by heavy rollers. ”

“ For ordinary bricks the firing atmosphere should be oxidizing, and the finishing temperature should be adjusted to the nature of the clay, the object being to produce a hard strong brick, of good shape, that will not be too porous and will withstand the action of frost. ”

“ The Babylonians and Assyrians attained to a high degree of proficiency in brickmaking, notably in the manufacture of bricks having a coating of coloured glaze or enamel, which they largely used for wall decoration. The Chinese claim great antiquity for their clay industries, but it is not improbable that the knowledge of brickmaking travelled eastwards from Babylonia across the whole of Asia. It is believed that the art of making glazed bricks, so highly developed afterwards by the Chinese, found its way across Asia from the west, through Persia and northern India, to China. ”

“ The action of lime in bleaching the ferric oxide and producing a yellow instead of a red brick, has not been thoroughly investigated, but it seems probable that some compound is produced, between the lime and the oxide of iron, or between these two oxides and the free silica, entirely different from that produced by oxide of iron in the absence of lime. Such marls require a harder fire than the ordinary brick-clays in order to bring about the reaction between the lime and the other ingredients. ”

“ The introduction of machinery greatly helped the brickmaking industry in opening up new sources of supply of raw material in the shales and hardened clays of the sedimentary deposits of the older geologic formations, and, with the extended use of continuous firing plants, it has led to the establishment of large concerns where everything is co-ordinated for the production of enormous quantities of bricks at a minimum cost. ”

“ Plastic bricks take much longer to dry than semi-plastic; they shrink more and have a greater tendency to warp or twist.
The burning or firing of bricks is the most important factor in their production; for their strength and durability depend very largely on the character and degree of the firing to which they have been subjected. The action of the heat brings about certain chemical decompositions and re-combinations which entirely alter the physical character of the dry clay. ”

“ If the atmosphere is too moist the surface of the brick remains damp for a considerable time, and the moisture from the interior passes to the surface as water, carrying with it the soluble salts, which are deposited on the surface as the water slowly evaporates. ”

“ Down-draught kilns usually give a more regular fire and a higher percentage of well-fired bricks; and they are more economical in fuel consumption than up-draught kilns, while the hot gases, as they pass from the kiln, may be utilized for drying purposes, being conducted through flues under the floor of the drying-shed, on their way to the chimney. ”

“ Magnesia may replace lime to some extent in such marls, but the firing temperature must be higher when magnesia is present. Marls usually contract very little, if at all, in the burning, and generally produce a strong, square brick of fine texture and good colour. When under-fired, marl bricks are very liable to disintegrate under the action of the weather, and great care must be exercised in burning them at a sufficiently high temperature. ”

“ The site of the ancient city of Babylon is still marked by huge mounds of bricks, the ruins of its great walls, towers and palaces, although it has been the custom for centuries to carry away from these heaps the bricks required for the building of the modern towns in the surrounding country. ”

“ All clays contain more or less free silica in the form of sand, and usually a small percentage of undecomposed felspar. The most important ingredient, after the clay-substance and the sand, is oxide of iron; for the colour, and, to a less extent, the hardness and durability of the burnt bricks depend on its presence. ”

“ Gas firing is now being extensively applied to continuous kilns, natural gas in some instances being used in the United States of America; and the methods of construction and of firing are carried out with greater care and intelligence, the prime objects being economy of fuel and perfect control of firing. Pyrometers are coming into use for the control of the firing temperature, with the result that a constant and trustworthy product is turned put. ”

“ Coal or gas is burnt in the chamber or section that is being fired-up, the air necessary for the combustion being heated on its passage through the kilns that are cooling down, and the products of combustion, before entering the chimney flue, are drawn through a number of other kilns or chambers containing unfired bricks, which are thus gradually heated up by the otherwise waste-heat from the sections being fired. Continuous kilns produce a more evenly fired product than the intermittent kilns usually do, and, of course, at much less cost for fuel. ”

“ In the United Kingdom, and still more in Germany and the United States of America, great improvements have been made in machinery, firing-plant and organization, so that the whole manufacture is now being conducted on more scientific lines, to the great advantage of the industry. ”

“ Fires are kindled in the fire-mouths, and the clamp is allowed to go on burning until the fuel is consumed throughout. The clamp is then allowed to cool, after which it is taken down, and the bricks sorted; those that are under-fired being built up again in the next clamp for refiring. Sometimes the clamp takes the form of a temporary kiln, the outside being built of burnt bricks which are plastered over with clay, and the fire-mouths being larger and more carefully formed. ”

“ In practice, the clay is pushed from the pug along a smooth iron plate, which is provided with a wire cutting frame having a number of tightly stretched wires placed at certain distances apart, arranged so that they can be brought down upon, and through, the clay, and so many bricks cut off at intervals. ”

“ The Dutch and the Germans were the great brickmakers of Europe during the middle ages, although the Italians, from the 14th to the 15th century, revived and developed the art of decorative brick-work or terra-cotta, and discovered the method of applying coloured enamels to these materials. ”

“ The pug-mill consists of a box or trough having a feed hole at one end and a delivery hole or nose at the other end, and provided with a central shaft which carries knives and cutters so arranged that when the shaft revolves they cut and knead the clay, and at the same time force it towards and through the delivery nose. ”

“ There are many differences of detail in the manufacture, but the general method is in all cases the same. Dry sand is intimately mixed with about one-tenth of its weight of powdered slaked lime, the mixture is then slightly moistened with water and afterwards moulded into bricks under powerful presses, capable of exerting a pressure of about 60 tons per sq. in. After removal from the press the bricks are immediately placed in huge steel cylinders usually 60 to 80 ft. ”

“ It consists of a single firing-chamber in which the unfired bricks are placed, and in the walls of which are contrived a number of fire-mouths where wood or coal is burned. In the older forms known as up-draught kilns, the products of combustion pass from the fire-mouth, through flues, into the bottom of the firing-chamber, and thence directly upwards and out at the top. The modern plan is to introduce the products of combustion near the top, or crown, of the kiln, and to draw them downwards through holes in the bottom which lead to flues connected with an independent chimney. ”

“ In many recent presses, especially where semi-plastic clay is used, the brick is pressed simultaneously from top and bottom, a second ram, working upwards from beneath, giving the additional pressure. ”

“ Such presses are generally made of iron throughout, although other metals are used, occasionally, for the moulds and dies. The greatest variations found in brick presses are in the means adopted for actuating the ram ”