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1. Materials and Method of
Construction
Brick, Brick Masonry
Manufacturing of Bricks
Munawar Hussain
Civil Engineering Department
MNS-University of Engineering and Technology
Multan

2. BRICK MASONRY
The art of building structures using bricks and binding
materials like cement (mortar) is called brick masonry.
STONE MASONRY
The art of building structures using stones and binding
materials like cement (mortar) is called stone masonry.
BLOCK MASONRY
The art of building structures
using concrete blocks with binding
materials like cement (mortar)
is called block masonry.

3. BLOCK MASONRY

4. Basic Terms of Brick
1. Header
2. Stretcher
Brick is a basic building unit which is
in the form of rectangular block.
Standard size (Normal size)
9'' ×4½" ×3"
or
(225 mm x112 mmx 75 mm)

5. Basics Terms
• Arises
The edges formed by the
intersection of plane surfaces of a
brick are called arises.
• Frog
The depression provided in the
face of a brick during its
manufacturing is called the frog.
• Course
Each horizontal layer of bricks
laid in mortar is called course.
Arises
Frog
Courses

6. Quoins
The external corners of a wall are
called Quoins. And the bricks
forming quoins are called quoin
bricks. e.g. quoin header or
quoins stretcher.
Perpends
The vertical joints of the bricks
are called Perpends. The
perpends of the alternate courses
should be in the same vertical
line
Perpends
Quoin
Header
Quoin
Stretcher
Basic Terms

7. Basic Terms
Jambs
It is the vertical sides of door or window opening
to which the door is or window frame is attached.
Soffit
The under surface of any structural member such
as a lintel, a slab is called Soffit.
Sill
The horizontal surface at the
bottom side of a door or
window opening is called sill.

8. Mortar
The mixture of binding material and fine aggregate forming a
workable paste is called mortar.
Grout or slurry
The thin paste of cement is called grout or slurry. It is used to fill
the joints.
Lintel
A small horizontal member to span up small opening is called lintel.

9. Types of Closer : King Closer

10. Types of Closer : Queen Closer
1/2
1/2

11. Types of Closer : Mitred Closer
Angle 45° to 60°

12. Types of Closer : Bevelled Closer
1/2

13. Bat 1/2
1/2

14. Bat 3/4
3/4

15. Bevelled Bat

16. Types of Bond
Stretcher Bond
Header Bond
English Bond
Flemish Bond

17. Stretcher Bond

18. Header Bond

19. English Bond

20. Flemish Bond

21. Corner Junctions(English Bond & Flemish Bond)

22. Tee Junctions (English Bond & Flemish Bond)

23. Cross Junction & Squint Junctions

24. Test for Bricks
A brick is generally subjected to the following tests to
find for the construction work,
(1) Absorption
(2) Crushing strength
(3) Hardness
(4) Presence of soluble salts
(5) Shape and size
(6) Soundness
(7) Structure

25. 1) Absorption:
A brick is taken and it is weighed dry. It is then immersed in water for a
period of 16 hours. It is weighed again and the difference in weight
indicates the amount of water absorbed by the brick. It should not in exceed
20 per cent of weight of dry brick.

26. (2) Compressive/Crushing strength of Bricks:
The crushing strength of a brick is found out by placing it in a compression
testing machine. It is pressed till it breaks.
The minimum crushing or compressive strength of bricks is 3.50 N/mm2.

27. (3) Hardness test on bricks:
In this test, a scratch is made on brick surface with
the help of a finger nail. If no impression is left on
the surface, the brick is sufficiently hard.

28. (4) Presence of soluble salts:
1) The soluble salts, cause
efflorescence on the surface of
bricks.
2) For finding out the presence of
soluble salts in a brick, it is
immersed in water for 24
hours. It is then taken out and
allowed to dry in shade.
3) The Presence of white deposits
on indicates presence of soluble
salts.

29. (4) Presence of soluble salts:

30. (5) Shape and size:
1) In this test, a brick is closely inspected. It should be of standard size
and its shape should be truly rectangular with sharp edges.
2) For this purpose, 20 bricks of standard size (225 mm x 112.5 mm x 75
mm) are selected at random and they are stacked lengthwise, along the
width and along the height.
3) For good quality bricks, the
results should be within the
following permissible limits

31. (6) Soundness test on brick:
In this test, the two bricks are taken and they are
struck with each other. The bricks should not break
and a clear ringing sound should be produced.

32. (7) Structure of a brick:
A brick is broken and its structure is examined. It
should be homogeneous, compact and free from any
defects such as holes, lumps, etc.

33. Classification of Bricks
The classification of bricks is as follows:
(i)unburnt or sun-dried bricks; and
(ii)burnt bricks.
The unburnt or sun-dried bricks are those bricks
• which are dried with the help of heat that is
received from sun after the process of
moulding.
• The unburnt bricks can only be used in the
construction of simple temporary and cheap
structures.
• Unburnt bricks should not be used at places
exposed to heavy rains

34. Classification of Burnt Bricks
The bricks used in construction works are burnt bricks and
they are classified into the following four categories:
(1) First class bricks
(2) Second class bricks
(3) Third class bricks
(4) Fourth class bricks

35. First class bricks:
Specifications:
(1) Plain surface, sharp edges and size with tolerance in
dimensions +3%
(2) Uniform red or brownish colored.
(3) High crushing strength, not less than 10.7 N/mm2
(4) Machine moulded
(5) Efflorescence- NIL
(6) Water absorption less than 15%.
USE: They are used for the exterior wall brick works,
short columns and arches.

36. Second class bricks:
Specifications:
(1) Slightly uneven faces and edges with tolerance in
dimensions +8%
(2) Uniform colored but may be slightly over burnt.
(3) High crushing strength, not less than 7 N/mm2
(4) Hand moulded
(5) Efflorescence-Little
(6) Water absorption less than 20%.
USE: They are used for internal walls and compound
walls.

37. Third class bricks:
Specifications:
(1) May be distorted with blunt edges.
(2) Over burnt or under burnt and non-uniform color.
(3) Crushing strength, not less than 3.5N/mm2
(4) Hand moulded
(5) Efflorescence- Large
(6) Water absorption less than 25%.
USES: They are used for flooring, paving, small brick
foundations and brick blast.

38. 1) These are overburnt bricks with irregular shape and
dark colour.
2) These bricks are used as aggregate for concrete
in foundations, brick floors, surkhi, roads, etc. because
of the fact that the overburnt bricks have a compact
structure and hence they are sometimes found to be
stronger than even the first class bricks.
3) It is thus seen that the above classification of bricks is
based on the of manufacturing or preparing bricks.
Fourth class bricks:

39. Classification based on shape
The ordinary bricks are rectangular solids. But sometimes the
bricks are given different shapes to make them suitable for
particular type of construction. Here we have enlisted different
types of bricks available with various shapes:
Bullnose brick:
1. A brick moulded with a rounded angle is termed as a bullnose.
2. This type of brick is used for a rounded quoin.

40. Channel bricks:
1. These types of bricks are moulded to the shape of a
gutter or a channel and they are often glazed.
2. These bricks are used to function as drains..

41. Coping bricks:
It is provided at the top of a wall to avoid dampness. They
are specially designed bricks to cover the tops of brick
parapet walls.
These bricks are made to suit the thickness of walls on
which coping is to be provided.

42. Hollow bricks:
1. They are light in weight about one-third the weight of the
ordinary brick of the same size.
2. These bricks leads to speedy construction.
3. They also reduce the transmission of heat, sound and
damp.

43. Paving bricks:
1. These bricks are prepared from clay containing a higher
percentage of iron.
2. Such bricks resist better the abrasive action of traffic.
3. The paving bricks may be plain or chequered.
4. These bricks are extensively used for garden walks,
street pavements, stable floors, etc. These types of
bricks also render the floor less slippery.

44. Perforated bricks:
1. These bricks contain cylindrical holes throughout their
thickness.
2. These bricks are light in weight and they require less
quantity of clay for their preparation.
3. The drying and burning of these bricks are also easy.
4. They may be of different shapes like circular, square
rectangular or any other regular shape in cross-section.
5. The compressive strength of perforated bricks should not be
less than 7 N/mm2 .

45. Purpose-made bricks:
1. In order to achieve certain purpose, these types of bricks are
made.
2. Engineering bricks are prepared for constructions where high
durability, compression strength and adequate resistance to
sudden shocks are required.
3. These types of bricks are usually more costly than the ordinary
bricks. But they grant safe, clean and quick construction.

46. Masons tools in Bick masonry
• Trowel
• Brick hammer
• Lines and pins
• Spirit level and water level
• Straight edge
• Plumb Line
• Mason’s square (guniya)
• Tape (steel)

47. Mason’s
Tools

48. Use of Trowel & Lines and Pins

49. Use of Plumb
bob and Edge

50. MANUFACTURING
OF BRICKS

51. Clay Bricks
Manufactured from clay. The basic compositions of clay
brick are:
i. Silica (SiO2) – 60%
ii. Alumina (Clay) (Al2O3) – 20%
iii. Remaining ingredients – 20%
• Remaining ingredients such as:
i. Calcium oxide (Lime)
ii. Iron oxide – give red colour
iii. Manganese
iv. Magnesium oxide

52. Functions of Ingredients
• Silica –silica (sand), if added to clay in suitable
proportion makes a brick hard and prevents it from
warping and shrinking on drying.
• Alumina – Alumina is main constituent of every clay.
On the addition of water, clay becomes plastic and can
be moulded into shape.
• Lime – It helps to lower the fusion temperature, i.e. it
helps silica to fuse at lower temperature and thus helps
to bind the particle together. It also prevents shrinkage
of raw bricks

53. Harmful ingredients
• Alkalise – Lower the fusion temperature and melts the
brick, changes it shape or get twisted. Also these salts
have hygroscopic action.
• Iron pyrites – During burning, iron pyrites due to high
temperature oxidise, decompose and disintegrate brick
into pieces.
• Organic matter –Although the presence of organic
matter in brick helps it burning, this causes porosity in
the bricks. The presence of organic matter such as roots,
dry leaves, in brick should be avoided.

54. MANUFACTURING OF BRICKS
1. Preparation of brick earth
2. Moulding of bricks
3. Drying of bricks
4. Burning of bricks

55. Removal of loose soil
The top layer of the loose soil about 30 cm depth contains a lot of impurities
like organic matter and hence it should be taken out and thrown away.
Digging, spreading and cleaning
The earth is then dug out from the ground. This earth is spread into heaps
about 50 to 150 cm height.
Weathering
The earth is then exposed to atmosphere for softening. The period may be of
few weeks to a season.
Blending and tempering
The clay is then mixed with suitable ingredients. It is carried out by taking a
small portion of clay every time and by turning it up and down in vertical
direction (Pug Mill).
MANUFACTURING OF BRICKS

56. MATERIAL PREPARATION

57. Pug Mill

58. MOULDING
Hand moulding
When moulding is done with hand it is called hand moulding.
A wooden rectangular mould made in the shape of a brick is
normally used for this purpose.
Machine moulding
The clay is placed in the machine, it comes out through the opening
under pressure.
It is cut to bricks by steel wires fixed into frames.

59. DRYING OF BRICKS
• Wet brick from molding or cutting machines contain 7 to 30
percent moisture, depending upon the forming method.
• Before the firing process begins, most of this water is evaporated
in dryer chambers at temperatures ranging from about 100 ºF to
400 ºF (38 ºC to 204 ºC).
• The extent of drying time, which varies with different clays,
usually is between 24 to 48 hours.
• Heat and humidity must be carefully regulated to avoid cracking
in the brick.

60. BURNING OF BRICKS
(A) INTERMITTENT KILN - CLAMP , SCOVE
(Loading, unloading, Cooling, and Burning of bricks)
Highly inefficient & labor-intensive.
Most common, most polluting
Temporary Structures
A typical scove kiln.

61. (B) CONTINOUS KILN BURNING
(HOFFMAN, BULL’S TRENCH, VERTICAL SHAFT )
These are permanent structures.
Burning is done continuously in kilns.
Bricks from kilns are of correct size, perfect shape and good quality.
Rate of burning is also high in kilns.
But initial investment for kiln is very high.
There are two well-known continuous kilns:
1. BULL’S TRENCH Kiln
2. Hoffman Kiln

62. BULL’S TRENCH KILN
Bull's trench kiln consist of a rectangular, circular or oval
plan shape. They are constructed below the ground level by
excavating a trench of the required width for the given
capacity of brick manufacturing.
This Trench is divided generally in 12 chambers so that 2
numbers of cycles of brick burning can take place at the
same time for the larger production of the bricks.
Once fire is started it constantly travels from one chamber
to the other chamber, while other operations like loading,
unloading, cooling, burning and preheating taking place
simultaneously.
Its manufacturing capacity of about 20,000 bricks per day.

63. BULL’S TRENCH KILN
Used in India, Pakistan, Nepal, Bangladesh
“Movable chimney” (MC) and “Fixed” Fixed (FC)
MCBTK banned (but still used) in India, parts of Nepal & Pakistan
due to very high emissions

64. The main difference between the Bull's trench kiln and the
Hoffman kilns are:
1.Hoffman's kiln is an over the ground structure while
Bull's Trench Kiln is an underground structure.
2.Hoffman's kiln have a permanent roof while Bull's trench
Kiln do not have so it former can be used in 12 months a
year to manufacture bricks but later is stopped in the
monsoon season.
Hoffman's kiln is generally circular in plan, and is
constructed over the ground. The whole structure is divided
into the 12 chambers and all the processes takes place
simultaneously like in Bull's trench Kiln.
HOFFMANN KILN

65. HOFFMANN KILN – ORIGINAL

66. HOFFMANN KILN – MODERN & HYBRID
 Widely used in China
= 90% of bricks Can use coal or
natural gas

67. Loaded at top, bricks removed
from bottom
• High efficiency, low emissions
• Kiln of choice for aid agencies
India, Nepal, Pakistan, Vietnam
VERTICAL SHAFT BRICK KILN (VSBK)

68. Reinforced brick Masonry
•The brick masonry done by embedding reinforcement
in rich cement mortar is called Reinforced brick
masonry.
•Reinforcement used may be in the form of
• Steel bars
• Hoop iron
• Wire mesh

69. Reinforced Brick Masonry

70. Constructions of Brick Masonry
•It is the art of laying bricks in a proper bond with
specified mortar to form a structure.
It involves the following activities…
•Selection of bricks
•Stacking of bricks
•Soaking of bricks
•Preparation of mortar (ASTM Specifications C 270, "Mortar for Unit Masonry“)
•Laying of bricks

71. General Principles and precautions in
Brick Masonry
• English bond should be used if not specified.
• Bricks used should be well burnt and should be uniform
in size, shape and colour.
• For facing work selected bricks should be used.
• Curing of bricks should be done for at least 2 hours.
• Bricks should be laid with frogs pointing upward or as
specified by the Engineer In charge.
• Mortar used in brick masonry should be of good quality.
• Brick bats are avoided.

74. Piers of Bricks

75. A cornice is any horizontal
decorative molding that crowns a
building.
Frieze
any decorative band on an outside
wall, bearing lettering or sculpture
etc.

76. Advantages of Brick
1.Brick will not burn, buckle or melt.
2.Brick will not rust and corrode.
3.Brick will not require constant maintenance.
4.Economical (Raw material is easily available)
5.Hard and durable
6.Compressive strength is good enough for ordinary
construction
7.Different orientations and sizes give different surface
textures
8.Reusable and Recyclable
9.Highly fire resistant

77. Disadvantages of Bricks
1. Time consuming construction
2. Cannot be used in high seismic zones
3. Since bricks absorb water easily, therefore, it causes
fluorescence
4. Very Less tensile strength
5. Cleaning brick surfaces is a hard job
6. Color of low quality brick changes when exposed to sun
for a long period of time