2.  Clay Bricks are made of Silica, Alumina, Lime, Iron, Manganese, Sulfur, and Phosphates. They are poor conductors and are non combustible.  Young’s modulus = 1.5 x 10 6 psi – 5.0 x 10 6 psi  Modulus of Rupture = 500 – 3800 psi  Density = 125 pcf  Common uses include building, facing, flooring, and paving.

4.  3 Types of Clay are used to make Brick  Surface Clays – sedimentary formations found on the surface  Shales – clays subject to high pressures until nearly hardened into slate  Fire Clays – mined at deeper levels than other clays  Mined in open pits then transported to plant storage areas

6.  Dry Pan Crushers- Breaks large chunks of clay or shale  Grinders- pulverizes the clay to a fine consistency (Muller Wheels)  Important to have clays dry when grinding

7.  Passes through Vibrating Screen, Scalping Screen  Coarse material left goes back to grinder  Hammer mill  Large particles inhibit the durability of the brick

9.  Two steps in the forming process  Tempering  Water is added to the clay in a pug mill  Molding  Stiff Mud  Soft Mud  Dry-Press

11.  The moisture content of the formed clay is reduced, not eliminated, so that the brick will not explode during the firing process.  The clay is sent through a drying chamber for 24 to 48 hours at 100 to 400 deg F.  Heat and humidity must be regulated to avoid cracking in the brick

13.  Tunnel Kiln – Most Common, four stages  Final Drying and Dehydration: 300° F - 1800° F  Oxidation: 1000° F - 1800° F  Vitrification: 1600° F - 2400° F  Flashing: Varies depending on desired color

14.  Tunnel Kiln-10 hours  Rate of Cooling has direct effect on color  Dehacking  Unloading a kiln after cooling  Bricks are sorted, graded, then packaged.

15.  Millberg, M. L. "How Brick Is Made - Material, Production Process, Manufacture, Making, Used, Processing, Dimensions, Industry, Raw Materials, The Manufacturing Process of Brick, Quality Control." How Products Are Made. How Products Are Made. Web. 29 Nov. 2010..  "Brick Manufacturing." Brickwork Design Guide by Glen-Gery Brick. Web. 29 Nov. 2010. http://www.glengerybrick.com/>.  "Manufacturing of Brick." Brick Industry Association - BIA. 2006. Web. 29 Nov. 2010..