BRICKS AND TILES

FIRE-CLAY OR REFRACTORY CLAY

Fire-clay is a term, generally applied, to include those sedimentary or residual clays which
vitrify at a very high temperature and which, when so burnt, possess great resistance to
heat. These are pure hydrated silicates of alumina and contain a large proportion of silica
55–75%, alumina 20–35%, iron oxide 2–5% with about 1 percent of lime, magnesia
and alkalies. The greater the percentage of alumina, the more refractory clay will be. Fire
clays are capable of resisting very high temperatures up to 1700°C without melting or
softening and resist spalling as well. The presence of a small percentage of lime and
magnesia and alkalies help to melt the clay particles more firmly, whereas a large
percentage of lime and magnesia tend to melt the clay at low temperatures. Iron oxide or
other alkalies reduce refractory qualities of fire clay. The fire clay is used for
manufacturing of fire bricks, in furnace linings, hollow tiles, and crucibles.

FIRE-CLAY OR REFRACTORY BRICKS

Fire-clay bricks are made from fire-clay. The process of manufacturing is similar to an
ordinary brick, but burnt at very high temperature in special kilns. The raw materials
used for the manufacturing of fire bricks consists of flint clay and grog (burnt fire clay)
as non-plastic materials and soft fire clay as plastic material. Fire clay mortar is used for
laying the refractory bricks.

Properties
1. The colour is whitish yellow or light brown.
2. The water absorption of fire-clay bricks varies from 4–10%.
2
3. The minimum average compressive strength of these bricks should be 3.5 N/mm .

Uses: Refractory bricks are used for lining of furnaces, ovens, kilns, boilers and
chimneys.
The principal types of fire-clay bricks are as follows:

1-Acid Refractory Bricks consists of silica bricks (95–97% silica and 1–2% lime) and
ganister bricks (ganister—a hard coloured sand stone containing 10 percent clay and 2
percent of lime), used in lining of furnaces having siliceous and acidic slag, steel industry
etc. The softening temperature ranges from 1700° to 1800°C. Silica bricks are hard
and also possess good refractoriness but these have tendency to spall during rapid
temperature change therefore, cannot be used for lining of those furnaces, which have
to be cooled and reheated frequently.

2-Basic Refractory Bricks consists of magnesia bricks (magnesia minimum 85

percent, calcium oxide maximum 25 percent and silica maximum 5.5 percent) and bauxite
bricks (minimum 85 percent aluminium oxide and maximum 20 percent clay). These
are used for lining of furnaces having basic slag. Due to high thermal expansion and
consequent poor resistance to spalling, the use of these bricks is restricted to copper
metallurgy and basic open hearth.

3-Neutral Refractory Bricks consists of chromite bricks (50 percent chrome and iron
ore containing 30 percent iron oxide and bauxite containing 15 percent aluminium and
5 percent silica) and chrome magnesite bricks (Cr2O3 18 percent, MgO 30 percent). The
neutral refractory bricks are suitable at places where acidic and basic linings are to be
separated, e.g. for lining of copper reverberatory furnace.

TILES

Tiles are thin slabs of low melting clays used for various purposes in construction. Tiles give
a pleasing appearance and good service properties. Roofing tiles, flooring tiles, wall tiles
etc. are some of the examples. Due to considerable mass, labour-consuming
manufacturing, and appreciable transportation charges, the relative significance of
clay tiles has reduced. These are durable and impervious to water, resist abrasion well
and easily washable. White and red burning clays, fire clays and shales are used in the
manufacture of floor tiles. Wall tiles differ from floor tiles principally in design and in
degree of burning. Wall tiles are burned at a comparatively low temperature, glazed, and
burnt again in kiln at a still lower temperature.
Manufacturing
Tiles are made in the same manner as bricks, but are thinner and lighter, so require more
care. These are manufactured from a clay mass with or without admixtures and colouring
pigments, by moulding and subsequent burning until baked, up to about 1300 °C. The
clay should be highly plastic with lean admixtures and fusing agents to lower the
melting point. These are moulded in machines and are commonly burned in continues
kilns.
Flat Roofing/Terracing Tiles: The flat roofing/ terracing clay tiles may be hand
moulded or machine moulded. The typical roofing clay tile has size of 9” x 4.5” x 1.5”
(thickness is half of the clay brick).

Characteristics
A good clay roofing tile should have the following properties:

1. uniform texture.
2. accurate size and shape.
3. free from defects like flaws, cracks and non-uniform burning.
4. water absorption should be less than 15 percent.
5. resistant to atmosphere and dampness.
6. durability.

Uses
These are usually used as roofing material and also used to give a pleasing look.

Flooring Tiles
The flooring tiles are available in various sizes. The average dimensions should not vary
by more than ±5 mm and for a given area or space, the dimensions of individual tile
should not vary by more than ±2 %. For thickness, these limits are ±2 mm and ±1 mm
respectively.

TERRACOTTA

It is an Italian word, Terra means clay and Cotta means burnt. Terracotta is refractory
clay product and is used in ornamental parts of buildings. The clay used for its
manufacturing should be of superior quality and should have sufficient iron and alkaline
contents. By varying iron oxide in clay, desired colour can be obtained. The clay is mixed
with powdered glass, pottery and sand ground to fine powder, and all pugged several
times till mix gets uniform state and soft for moulding. Terracotta is impervious, hard
and cheap. When properly made, the material weathers well and because of its glazed
surface can be cleaned easily. The product is burnt in special kilns.

Preparation of Clay: The clay is mixed thoroughly with water. Powdered pottery,
glass and white sand are added to it in sufficient proportions. It is then mixed with
spades. This mix is then placed in wooden boxes and allows the surplus water to drain
off. Thereafter the mix is passed several times through pug mill.

Moulding and Drying: Special porous moulds are made of Plaster of Paris or of
zinc. The pugged clay is pressed into moulds. The dried articles are taken out of the
moulds after a few days and then dried slowly.

Burning: Terracotta is burned between 1100–1200 °C in the muffle furnace with care to
get uniform colour.

Composition
Dry clay 50–60% Ground glass 8–10%
Crushed pottery 20% Clean white sand 10–20%

Uses
1. Hollow blocks of terracotta are used for masonry.
2. Cornices and arches.
3. Ornamental works.
4. Being fire resistant, terracotta is suitable as casing for steel columns and beams.
5. Porous terracotta is used for sound insulation.

Classification: Terracotta is of two types, porous and the polished.

Porous Terracotta: It is manufactured by mixing saw dust or finely fragmented cork
in the clay and has the following properties.

1. Light weight.
2. Resistant to weathering actions.
3. Fire resistant.
4. Can be nailed and sawn to various shapes.
5. Sound resistant.
6. Low strength—used only for ornamental works.

Polished Terracotta: It is highly glazed architectural terracotta with relatively coarse

body. These are made from refractory clays with addition of quartz sand and fusing agents
such as chalk. The polished terracotta is also called terracotta twice burnt. The first
burning is called biscutting and is done at 650°C. Then, this product is cooled with glazed
solution which imparts texture and colour. Thereafter, it is dried and burned at 1200°C.
The material at this stage;
1. is hard, strong and durable.
2. can be given different colours.
3. is leak proof (water absorption < 12 percent) and can be easily cleaned.
4. is resistant to chemical action.
5. is resistant to weathering actions and fire resistant.

PORCELAIN

A high grade ceramic ware having white colour, zero water absorption and glazed
surface, which can be soft or hard, consists of finely dispersed clay, kaolin, quartz and
felspar, baked at high temperature and covered with a coloured or transparent glaze.
The glazing material is applied before burning. At high temperatures, the felspar
particles fuse and bind the other constituents into a hard, dense, and vitreous mass.
High temperature ensures non-porosity and a better product. Because of white colour, it
is also called whiteware which is of two types:

Soft Porcelain is made from white clay to which flint is added.

Hard Porcelain is made from china clay or kaolin with quartz and felspar is added as
filler.

Composition
China clay 50–60%
Ordinary clay 5%
Whiting pigment < 1%
Felspar 20%

Characteristics
1. Low (zero) water absorption.
2. Hard and glazed.
3. Good refractory material.
4. Good electric insulator.

Uses: Porcelain is used for manufacturing o f sanitary wares, containers and

crucibles, reactor chambers and electric insulators.

Note: A special type of porcelain known as Ziron Porcelain is used in automobile industry.
Its composition is as follows:
Iron 60%
Clay 15-30%

STONEWARE

A hard ceramic material resembling porcelain with a different colour, usually grey or
brownish, is made from refractory clay mixed with crushed pottery, stones and sand
burned at high temperatures and cooled slowly. The clay used for making stoneware
consists of about 75 percent silica and 25 percent alumina. Iron oxide is added to give
colour.

Characteristics
1. Hard, compact, strong and durable material.
2. Gives ringing sound when struck with each other.
3. Glazed stoneware is resistant to chemical and weathering actions.
4. Gives good finish and appearance.

Uses
1. Light sanitary wares, e.g. wash basins, water closets, etc.
2. Drain pipes and fittings.
3. Road paving materials.
4. Flooring tiles and wall tiles in toilets and kitchens.

EARTHENWARE

These are made by burning the ordinary clay at low temperature and cooling slowly. To
check shrinkage, sand and crushed pottery are mixed with clay, which also increases
the toughness, hardness and strength of the ware.

Characteristics
1. Soft, porous and weak.
2. Glazed earthenware becomes resistant to weathering actions.

Uses: Earthenware is used for manufacturing drain pipes, lavatory fittings and light
weight partition walls.

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