Bricks, precast stone and concrete are essential for the construction of our homes, schools, workplaces and even decorative items. They are the building blocks to make many of the structures we use in our daily lives. Brick-making has been refined over the years to what we now know as modern brick-making.
In this blog, we’ll outline everything you need to know about how bricks are made.
Manufacturing process
There are several steps in the brick manufacturing process.
Crushing and grinding
Firstly, the raw clay is crushed and ground in a jaw crusher, which helps to turn the material into smaller particles. It is at this stage that the other materials will be added and different-sized pieces will be separated while larger pieces are put to one side for pummelling so they can be used in another batch.
Forming bricks
Next, the bricks will be formed into whichever shape is needed. The most popular method at this stage is Extrusion (or Wirecut) because it’s the lowest-cost option for producing bricks at scale. This is commonly considered the mass-produced option. However, there are three common methods for brick production.
- Extrusion (or Wirecut): After crushing, the clay mixture is fed into one end of a pug mill, and the material will be folded together to ensure it is properly combined. It will then go through an extruder, where the air is removed and the material is compacted. The brick shape is then formed by pushing the material back through a die (an orifice at the end of the machine shaped into the cross-section of a brick). Sections of a desired length are then cut with saws or wires.
- Moulding: In this method, soft wet clay is shaped by a mould, which is usually a wooden box coated with sand, and left to dry. However, for larger scale manufacturing, a hydraulic press will compact the material into the required shape. The sand helps with the removal of the brick and also gives the surface a different texture.
- Pressing: Similarly to the moulding method, this way uses a much thicker clay and greater force in pressing. Because the thicker clay has a lower water content, it provides a more accurate, sharper-edged brick. It is also placed in a die and then compacted with a steel plunger which can be set at different pressures. This is typically a more expensive process as it requires longer firing - but it produces more durable bricks.
Finally, the bricks will be dried and fired in a kiln. If you’re looking for quality cast stone suppliers for a variety of quality cast stone products and precast stone, get in touch with Shropshire Brick & Stone today. We can provide you with quality bricks and precast stone.
Comments