Brickmaking

“ 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. ”

“ Although the best bricks are still pressed from tempered or plastic clay, there has recently been a great development in the manufacture of semi-plastic or dust-made bricks, especially in those districts where shales are used for brickmaking. These semi-plastic bricks are stamped out of ground shale that has been sufficiently moistened with water to enable it to bind together. The hard-clay, or shale, is crushed under heavy rollers in an iron grinding-pan having a perforated bottom through which the crushed clay passes, when sufficiently fine, into a small compartment underneath. ”

“ BURNING BRICK WITH CRUDE OIL FUEL.
At the present time there is not the least reason why either wood, coal, or any other solid fuel should be used for the burning of brick. This style of burning brick belongs to a past age. The art of brickmaking has made tremendous progress during the past quarter of a century. It is no longer the art of the ignorant; brains, capital, experience, science, wide and general knowledge, must in these days be the property of the successful brick manufacturer. ”

“ Enough has now been said to show that stupendous quantities of mineral matter derived from the destruction of the land are sent down to the sea by natural agencies, and we may at once state that a very large proportion of this, which finds a resting-place in and about the mouths of the rivers and their backwaters, is material suitable for brickmaking at places where it is obtainable. Enormous quantities of muddy sediment, sand and gravel, however, never reach as far as the sea with great rivers. This material is arrested at sundry convenient spots, and, as a rule, forms excellent brick-earth. ”

“ Again, a brick cracked all over, not with superficial cracks only, but with those which go far into the interior, will not yield its quality by mere immersion in water. The water, it is true, finds its way right into the brick, but, as often as not, the sides of the cracks are perfectly vitrified and almost damp proof, so that on lifting the brick out of the water the latter rolls off as though it were on “a duck’s back.” Yet such a brick, yielding but the merest fraction as a result of the immersion, may be utterly worthless when put into a building, because it would not be strong enough. ”

“ The brickmaker hardly needs to be told that if he places his bricks in the sun to dry, they, or a large percentage of them, will crack, and become practically worthless from a commercial standpoint. To dry a brick properly in the open air is a lengthy operation—too lengthy for many manufacturers, who, in consequence, have had recourse to artificial drying. Many a brickyard has had to be abandoned from the inability of the worker to produce bricks that did not crack at some period of the operation, either in the drying, or burning, or both. ”

“ We will assume that the brick has been either naturally or artificially dried, that no cracks have made their appearance, and that it is properly stacked in the kiln ready for burning. Now comes a most important part of the process. It is possible that any microscopic cracks will be closed by fusion or agglutination; but it more frequently happens that in unskilled hands the kiln is responsible for many cracked and “starred” bricks. To know exactly how to introduce the heat so gradually that the bricks shall not be impaired, is an art begotten only of considerable experience. ”

“ As a general rule, where care is exercised in the drying, the cracks arise from the brick-earth being too wet or plastic in the first place, and it cannot be too well understood that, cæteris paribus, the wetter the earth the more liable it is to crack during drying. The contraction, even when the unburnt brick is shielded, and in the open air, often proves too much for the material. Then we have that class of brick-earth composed of too much clay, and that would be improved by the addition of sand—just how much depends on the particular earth ”

“ The free use of metal ornaments, railings, for supporting signs, for down-pipes, &c., is unfortunate in not a few instances. At the point of junction between the metallic substance and the brick into which it is inserted, or in the immediate neighbourhood above which it is fastened, the brickwork is sure to be discoloured. ”

“ With the strength of brickwork, it is different, and it would seem rather remarkable, at first sight, that architects and engineers, who are every day using thousands of bricks, should have been at little pains to ascertain the “safe load” which this or that brick pier or wall would carry. Experience is, of course, of great value in all work of that description; but there is always the lurking suspicion that the engineer is making his piers too big, and that the architect is by no means running the thing close. ”

“ Where no sand is available, it frequently happens that brick-dust will answer the purpose, though this may be at the expense of homogeneity in the long run. In the semi-dry process of manufacture the initial causes of cracking are not present, the block having to contract so little that it may be taken from the press and stacked in the kiln for burning. ”

“ But what we more particularly desire to draw the reader’s attention to at the present stage, is not the employment of lime in making fire-bricks so much as its mixture with ordinary brick-earth, as in the manufacture of malm bricks. Sometimes the mixture has been effected by Nature, as is the case with true marls; but the brickmaker does not care so much for these, as without considerable and expensive artificial assistance they do not often make readily saleable bricks. ”

“ Turning to the second table, compiled for the most part from brickmakers’ circulars, and from the original results obtained for the late Building Exhibition, at the Agricultural Hall, all the experiments, we believe, having been carried out by Mr. David Kirkaldy, it will be noted that great variation in strength is apparent, following the different kinds of bricks. The highest result, 1064.2 tons per square foot, was obtained on a blue Staffordshire brick, though that is very closely run by bricks made from slate débris (1056.2 tons) from South Wales. ”

“ Again, the whole brick may be subject to the experiment, or only the half-brick. The faces placed between the dies of the crushing machine may not be flat, and they are most frequently irregular. If the dies are applied to such bricks it is evident that corners will be broken off before the brick has really suffered much, and that to get the best result the faces must either be made perfectly true and parallel to each other, or some other method adopted to put matters right. ”

“ Apart from the fierce and variable drying action of the open air, we have a fruitful source of cracks in the indentations made by stamping the makers’ name or trade-mark upon the blocks. With bricks burnt very hard this does not so much matter, but on the commoner kind of materials one may often perceive minute, hair-like cracks radiating from the indentations. We presume that in this age of advertising it is impossible to convince many makers of that fact, yet if full justice is to be done to the material, it will be better not to make any sharp or deep marks on the brick. ”

“ The manufacturer may test this for himself by heating a good, sound medium burnt brick to the temperature usually found in his kiln when unloading, and suddenly plunging it in snow. It is not, perhaps, that any one of these things is especially dangerous to the brick, but it is the combined effect of all of them trending in the same direction. We desire to be clearly understood on this point. The cracks produced may not seriously impair the strength of the brick; they may be merely superficial, and they mostly are. ”

“ Very porous bricks are not much affected, but the more compact kinds, and especially terra-cotta blocks, often suffer. These observations do not so much apply to our own country as to warmer climates; though we are not altogether without experience here. On being heated these materials expand; when made loosely, as in rubbers and the like, the effect of the expansion is not very manifest, because the motion is absorbed, so to speak, by the brick itself. ”

“ Unless the brick-earth be carefully prepared, however, the surfaces of the hard blocks produced by that process are liable to develop minute cracks. And here it may be stated that unless the clay, with brick96 dust or other foreign substance, be thoroughly incorporated prior to being sent under the press, and the whole ground very fine, it is impossible to prevent cracking during some part of the process. ”

“ Turning to a smaller matter, the hand-barrow coming from the drying stacks to the kiln is unprotected, which97 often means that a good brick is spoilt. Of course, we are not alluding, in this connexion, to what takes place during clamp stacking; the brick produced by such a process must take its chance. The method of stacking in the kiln or clamp is very often responsible for damage to the bricks. A common method is to build them sloping outwards, and all sorts of strains and stresses are thus set up, which have their effect in producing lines of weakness, if not of actual visible cracks. ”

“ In drying, the greatest care would have to be exercised to prevent undue shrinking, and, in any case, the earth would have to be very thoroughly incorporated to make a really serviceable brick. It is with earths of this character that the majority of brickmakers in embryo come to grief; they know not how to handle them successfully, and twisting, warping, cracking, and “bursting” follow as a natural consequence. It is a common and treacherous material, that could only be made to succeed by perseverance and wide experience. ”

“ On the other hand, we have red bricks in which the constituents are distinctly agglutinated by fusion, and the whole burnt thoroughly. The brick-earth of which these latter are made, would barely turn tint—would certainly not become red—at so low a temperature as that employed in producing the red in the non-agglutinated bricks alluded to.
It is not always an easy matter in burning a red brick to obtain two kilns full of the same tint, even in the same yard. When the employment of pyrometers becomes more general, that will be considerably simplified ”

“ In general, we have to consider whether the brick is strong enough for the purpose to which it is to be applied; and that depends much more on the manner in which it is built up, than on the strength of the105 individual brick. For ordinary building purposes almost any kind of brick is, per se, strong enough, and a mere inspection of the specimen suffices to carry conviction as to its suitability or otherwise in that respect. ”

“ If some substance were present in the rain that could readily form an alliance with an ingredient of the brick, and the union was capable of crystallising out, the surface of the brick would naturally form a convenient spot for the crystallisation to take place. To prevent it, we ought to know the composition of the air at the spot where the house is to be erected, and also the chemical and physical structure of the brick to be employed. ”

“ Good building bricks absorb from 6 to 12 per cent. in 24 hours, and with no greater absorption than 12 per cent. will ordinarily show from 7,000 to 10,000 or more pounds per square inch of ultimate crushing strength.
3. Poor building bricks will absorb one-seventh to one-fourth of their weight of water in 24 hours, and average a little more than one-half the transverse and crushing strength of good bricks.
4. An immersed brick is nearly saturated in the first hour of immersion, and in the remaining 23 hours the absorption is only five-tenths to eight-tenths of 1 per cent. ”

“ In spite of that, however, we find that the “crushing strength” is much more popular than the others. The reason, so far as brick manufacturers are concerned, is not far to seek. Architects demand that especial quality. “What is the ‘crushing strength’ of your bricks?” enquires the architect. And if the maker does not know, he stands a good chance of losing the order. Figures are demanded, and if the maker cannot produce a higher figure than his neighbour, woe betide him. But statistics are ever deceptive, and as applied to bricks in regard to their strength especially so. ”

“ This question of colour is the all-predominating one with most malm brickmakers.
54 We said just now that the fragments of limestone in the raw brick are reduced to lime on being burnt; some of the latter, however, as may be anticipated from our subsequent remarks, is engaged in forming a flux wherever possible in the immediate neighbourhood of such fragments: it is the “kernel” that is left which becomes “slacked,” and weakens the brick. The object of utilising the smallest particles only of the carbonate of lime is thus obvious ”

“ In an ordinary brick-earth, when more than 10 per cent. of iron is present, the clay is apt to burn bluish, however, and, in certain cases, almost black. With a smaller proportion of iron, and the application of intense heat, the same tint may result, and the brick become vitrified. ”