Making Bricks

 

Making Bricks and Pavers – These slides will take you on a step by step journey through the manufacturing process of our bricks and pavers.

Alternatively you can watch our short film here:

From piles of dry clay, through the mixing process, the extrusion process, cutting, trimming, and through to firing.

To produce a clay brick the raw materials are first crushed and ground. Natural clay minerals, including kaolin and shale, make up the main body of brick. Small amounts of manganese, barium, and other additives are blended with the clay to produce different shades, and barium carbonate is used to improve brick’s chemical resistance to the elements.

Then the ingredients are formed using the extrusion method. The pulverized ingredients are mixed togther with water, passed into a de-airing chamber (which removes the air to prevent cracking), compacted, and extruded out of a die of the desired shape.

A wide variety of coating materials and methods are used to produce brick of a certain color or surface texture such as sand of a glaze.

Once the bricks are formed they are dried to remove excess moisture that might otherwise cause cracking during the ensuing firing process.

Next, bricks are loaded onto carts and moved into large furnaces called  kilns.

The bricks are fired in a high temperature kiln and then cooled.
Firing hardens and strengthens the brick.  After firing they are left to cool.

Finally, they are  hand graded, stacked, and wrapped on pallets.

bricks are  fired in kiln
Bricks are fired in the kiln at over 1100 Celsius