Bricks Making Full Process - A to Z - How to Make Bricks

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The brick making process typically consists of the following steps.
1. Preparation Of Raw Materials
In this first stage, the soil is mined in steps and then laid on a leveled ground where it is cleaned of all sorts of impurities (like vegetation matter, stones, pebbles etc). Once the material is clear from all impurities it is left exposed to weather for few months, this process is known as weathering. After this, the soil is mixed with other material to prepare good brick earth. Post raw materials are mixed, it is tempered in a pug mill by thoroughly breaking, watering and kneading it.

2. Shaping Or Moulding

Initially, moulds used for shaping bricks were made of wood, and the makers used sand to ensure the bricks didn’t stick to the moulds. But today there are many other options available for this process. Depending on the quality of the end product, bricks are moulded in many different ways. The most common methods for shaping or moulding bricks are hand moulding and machine moulding.

Hand Moulding – The tempered is clay injected into a mould in such manner that it fills in all the corners. Extra clay is removed using a frame with wire or with a wooden strike. Once proper shape is ready, the mould is lifted and what remains on the ground is raw brick.

Machine Moulding – This method is used where large numbers of bricks are manufactured. Essentially there are two different types of machines used for moulding bricks:
Plastic Clay Machines – Here the clay is in a plastic state and it is forced into rectangular openings of a size which is equal to the length and breadth of the bricks. Further, these are cut into strips of a similar width of the bricks with the help of wires in frames.

Dry Clay Machines – Here dry clay is condensed to powder which is filled into moulds by the help of machines. These are then exposed to high pressure to form hard and well-shaped bricks.

3. Drying

Drying is one of the most important steps in the brick making process. Thinking why are bricks dried? The main reason is to avoid cracks, it is important to understand that damp bricks if taken directly for burning result in cracking. Drying bricks ensure that inadequate moisture is removed before the burning process. Also drying increases the overall strength of raw bricks making them ready to be stacked on greater heights in the kiln for the burning process without damaging it.

Usually, drying is done by simply placing the bricks in sheds which have open sides, this ensures free air circulation and protection from extreme weather conditions. The drying process of bricks varies from 7 to 14 days.

4. Firing or Burning

After drying, the bricks are fired to high temperatures in furnaces. Burning is another very important step in the brick making process. Bricks in India are burnt by two distinct methods listed below:

Pazawah Or Clamp Burning
Bhatta Or Kiln Burning
Talking about clamps now, this is a field kiln which is built from the green bricks which would be fired. Clamps vary in size and shape and are carefully oriented with respect to the direction of the wind. Once a clamp constructed and laid out, it needs to be insulated.

The process of firing takes place in several steps. The first step is pre-heating or water-smoking which removes the leftover water from the drying process. After this process comes the stage of firing, here clay bricks vitrify through a chemical process. Temperatures in the clamp must remain constant during this stage to complete vitrification. Cooling stage is the final one, here the temperature needs to be slow and steady.

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