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Lovely Professional University

Phagwara (Punjab)

Term Paper of Building Material and construction on Brick Work Structures

Submitted to:Mrs. Dolonchapa Prabhakar

Submitted by: Shubham Roll No. : - ROE130A23 Class: - E28E1 Course: - B. Tech -M.Tech(ECE)

Introduction:

Brick work is an important part of construction work done with the help of bricks and cement mortar. It is done with different quality of bricks with different ratios of cement mortar according to the requirement. It is done in different parts of the building/structure according to the requirement/ architectural design of the buildings. Brickwork is masonry produced by a bricklayer, using bricks and mortar to build up brick structures such as walls. Brickwork is also used to finish corners, door, and window openings, etc. in buildings made of other materials. Where the bricks are to remain fully visible, as opposed to being covered up by plaster or stucco, this is known as face-work or facing brickwork.

Brick: A brick is a block of ceramic material used in masonry construction, usually laid using various
kinds of mortar. It has been regarded as one of the longest lasting and strongest building materials used throughout history. Length of brick=2 X width of brick + thickness of mortar Height of brick= Width of brick 19 X 9 X 9 cm 10 X 4 X 1 cm

Fig1: A Commonly used Brick

Methods of manufacture: Bricks for building may be made from clay, shale, soft slate, calcium
silicate, concrete, or shaped from quarried stone. However, true bricks are ceramic, and therefore created by the action of heat and cooling. Clay is the most common material, with modern clay bricks formed in one of three processes - soft mud, dry press, or extruded. Normally, brick contains the following ingredients: 1. Silica (sand) - 50% to 60% by weight 2. Alumina (clay) - 20% to 30% by weight 3. Lime - 2 to 5% by weight 4. Iron oxide - 5 to 6% (not greater than 7%) by weight 5. Magnesia - less than 1% by weight

1) Mud Bricks: The soft mud method is the most common, as it is the most economical. It starts with
the raw clay, preferably in a mix with 25-30% sand to reduce shrinkage. The clay is first ground and mixed with water to the desired consistency. The clay is then pressed into steel moulds with a hydraulic press. The shaped clay is then fired ("burned") at 900-1000 C to achieve strength.

2) Rail kilns: In modern brickworks, this is usually done in a continuously fired tunnel kiln, in which the
bricks move slowly through the kiln on conveyors, rails, or kiln cars to achieve consistency for all bricks. The bricks often have added lime, ash, and organic matter to speed the burning.

3) Bull's Trench Kilns: An oval or circular trench, 69 meters wide, 2-2.5 meters deep, and 100150
meters in circumference, is dug. A tall exhaust chimney is constructed in the centre. Half or more of the trench is filled with unfired bricks which are stacked in an open lattice pattern to allow airflow. The lattice is capped with a roofing layer of finished brick. In operation, new green bricks, along with roofing bricks, are stacked at one end of the brick pile; cooled finished bricks are removed from the other end for transport. In the middle the brick workers create a firing zone by dropping fuel through access holes in the roof above the trench. The advantage of the BTK design is a much greater energy efficiency compared with clamp. Sheet metal or boards are used to route the airflow through the brick lattice so that fresh air flows first through the recently burned bricks, heating the air, then through the active burning zone. The air continues through the green brick zone, and finally out the chimney where the rising gases create suction which pulls air through the system. The reuse of heated air yields savings in fuel cost.

4) Dry Pressed bricks: The dry press method is similar to mud brick but starts with a much thicker clay
mix, so it forms more accurate, sharper-edged bricks. The greater force in pressing and the longer burn make this method more expensive.

5) Extruded bricks: For extruded bricks the clay is mixed with 10-15% water or 20-25% water. This is
forced through a die to create a long cable of material of the proper width and depth. This is then cut into bricks of the desired length by a wall of wires. Most structural bricks are made by this method, as it produces hard, dense bricks, and suitable dies can produce holes or other perforations. The introduction of holes reduces the volume of clay needed, and hence the cost. Hollow bricks are lighter and easier to handle, and have thermal properties different from solid bricks. The cut bricks are hardened by drying for 20 to 40 hours at 50 to 150 C before being fired. The heat for drying is often waste heat from the kiln.

6) Calcium Silicate bricks: The raw materials for calcium silicate bricks include lime mixed with quartz
crushed flint or crushed siliceous rock together with mineral colorants. The materials are mixed and left until the lime is completely hydrated; the mixture is then pressed into moulds and cured in an autoclave for two or three hours to speed the chemical hardening. The finished bricks are very accurate and uniform, although the sharp arises need careful handling to avoid damage to brick. The bricks can be made in a variety of colors, white are common but pastel shades can be achieved.

Classification of Bricks: 1) On the basis of Field Practice: First Class bricks: These bricks are table-moulded and of standard shape and they are burnt in kilns.
The surfaces and edges of the bricks are sharp, square, smooth and straight. These bricks are used for superior work of permanent nature. Water absorption 12-15% of its dry weight. Crushing strength of the brick should not be less than 10N/mm2

Fig 2. First Class Bricks

Second Class Bricks: These bricks are ground-moulded and they are burnt in kilns. The surface of
these bricks is somewhat rough and shape is also slightly irregular. These bricks may have hair cracks and their edges may not be sharp and uniform. These bricks are commonly used at places where brickwork is to be provided with a coat of plaster. Crushing strength of the brick should not be less than 7N/mm2

Fig 3. Second Class Brick

Third Class Bricks: These bricks are under burnt & ground-moulded and they are in clamps. These
bricks re not hard and they have rough surfaces with irregular and distorted edges. These bricks give dull sound when struck together. They are used for unimportant and temporary structures and at places where rainfall is not heavy.

Fig 4. Third Class Brick

Fourth Class Bricks: These are over burnt with irregular shape and dark color. These bricks are used
as aggregate for concrete in foundations, floors, roads, etc. Because of the fact that the over burnt bricks have a compact structure and hence they are sometimes found to be stronger that even the first class bricks.

Fig 5. Third Class Brick

2) On the basis of Manufacture :

Handmade: Usually made on a bench, in a mould, much as described above for a stock brick.
Because the clay isn't firmly compacted by machine, each brick normally has distinctive creasing known as a 'smile'. Very desirable, and the most expensive of the facings, but well worth it on prestige jobs.

Machine Made: Made by machines- wire cut bricks, pressed bricks, moulded bricks

Fig 6 machine made and handmade bricks respectively

3) On the basis of Finish


Sand faced brick Rustic Brick

4) On the basis of burning


Pale bricks Body Bricks Arch bricks

5) On the basis of types


Solid Perforated Hallow Cellular

Wall thickness and Construction: 1) Solid brickwork: The simplest type of wall is constructed in solid brickwork, normally one brick thick.
Bricks are laid in rows known as courses; the arrangement of headers and stretchers in each course gives rise to different patterns or bonds.

2) Cavity walls: In a cavity wall, two layers of brickwork are tied together with metal ties, with a cavity of
2 to 4 inches that may be filled with insulation.

3) Brick facing: A non-structural outer facing of brick is tied back to an internal structure: a layer of
block work, timber or metal studwork etc.

Fig7. A wall made by bricks


Terminology Used in Brick Work: 1) Positions:

Bond: A pattern in which brick is laid. Stretcher: A brick laid horizontally, flat with the long side of the brick exposed on the outer face
of a wall.

Header: A brick laid flat with the short end of the brick exposed. Soldier: A brick lay vertically with the narrow side exposed. Sailor: A brick lay vertically with the broad side exposed. Rowlock: A brick laid on the long, narrow side with the small or header side exposed. Shiner: A brick laid on the long narrow side with the broad side exposed

Fig 8. Six Brick laying Positions

2) Brick type: There are two main types of clay bricks: pressed and wire-cut. Pressed bricks usually
have a deep frog in one bedding surface and a shallow frog in the other. Wire-cut bricks usually have 3 or 4 holes through them constituting up to 25% of the total volume of the brick. Some perforated bricks have many smaller holes.

3) Brick Usage: There are three main categories of use, and both pressed bricks or wire-cut brick types
are used in all three categories:

Facing brickwork: Facing brickwork is the visible decorative work. Engineering brickwork: Engineering brickwork is often seen in bridges and large industrial
construction but may also be hidden in ground works where maximum durability is required, e.g.in manhole construction.

Common brickwork: Common brickwork is not usually seen and is used where engineering
qualities are not required; below ground in domestic buildings and internal walls, for instance.

4) Frog up/down: A frog is a recessed part of a surface of a brick. Pressed bricks are laid frog up
when maximum strength is required especially in engineering work. This method also increases the mass of a wall and decreases sound transmittance. Pressed bricks may be laid frog down; this method is favored by the bricklayer, since less mortar is required for bedding. There may also be a marginal increase in thermal insulation due to the entrapped air pockets. A disadvantage of this method is that, with bricks having a very deep V-shaped frog, there may be some difficulty in making reliable fixings to the wall when the fixing hits an air pocket.

5) Wire-cut: Wire Cut bricks may be laid either way up but some types of wire cuts have a textured face,
creating folds in the face of the brick, which is directional. It is advisable to lay these bricks with the folds hanging downward to maximize the weathering characteristics of the brick.

6) Ties: Ties or cavity ties are used to tie layers of brickwork into one another, to form a structural whole.
A common type is a figure-eight of twisted wire, in general stainless steel to avoid failure due to corrosion. The loop at either end is buried in the mortar bed as the wall is built up.

7) Mortar: Mortar is a mixture of sand, lime and Portland cement, mixed with water to a workable
consistency. It is applied with a bricklayer's trowel, and sets solid in a few hours. There are many different mixes and admixtures used to make mortars with different performance characteristics.

Brick Works Bond:


Bricks may be laid in a variety of bonds or patterns of headers and stretchers on a series of courses. In single-thickness walls, these are purely decorative, but, in double-thickness walls, they strengthen the wall by connecting the layers.

1) Flemish Bond : Flemish bond, also known as Dutch bond, has throughout history been considered
the most decorative bond, and for this reason was used extensively for dwellings until the adoption of the cavity wall. It is created by alternately laying headers and stretchers in a single course. The next course is laid so that a header lies in the middle of the stretcher in the course below. This bond is two bricks thick. It is quite difficult to lay Flemish bond properly, since for best effect all the perpendiculars need to be vertically aligned. If only one face of a Flemish bond wall is exposed, one-third of the bricks are not visible, and hence may be of low visual quality. This is a better ratio than for English bond, Flemish bond's main rival for load-bearing walls.

Fig9. Flemish Bond

2) English bond : English bond consists of alternating courses of headers and stretchers, with the
alternative headers centred over and under the vertical joints of the stretchers.

Fig10. English Bond

3) American Common Bond: By one definition, Common, American, or Scottish bond has one row of
headers to five of stretchers. American common bond is similar to the English Bond but the courses of headers are separated by approximately five courses of stretchers.

Fig11. American Common Bond

4) Stretcher Bond: Stretcher bond, also known as running bond, consists of bricks laid with only their
long narrow sides showing, overlapping midway with the courses of bricks below and above. It is the simplest repeating pattern, but, since it cannot be made with a bond to the bricks behind, it is suitable only for a wall one-half brick thick, the thinnest possible wall. Such a thin wall is not stable enough to stand

alone, and must be tied to a supporting structure. It is common in modern buildings, in particular as the outer face of a cavity wall, or as the facing to a timber or steel framed structure. Stretcher bond is now used in building garden and boundary walls that are stand alone by incorporating a layer of steel brickreinforcing mesh, laid every three or so courses, thus acting as headers in tying the two leaves together.

Fig12. Stretcher Bond

5) Monk Bond : Monk bond is a variant of Flemish bond, with two stretchers between the headers in
each row, and the headers centered over the join between the two stretchers in the row below. It was commonly used in the region around the Baltic Sea until turn of 13th and 14th centuries, then it was gradually replaced by Flemish bond.

6) Rat Trap Round: Rat-trap bond, also known as Chinese bond, is a type of garden wall bond similar
to Flemish, but consisting of rowlocks and shiners instead of headers and stretchers (the stretchers and headers are laid on their sides, with the bed face of the stretcher facing outward). This gives a wall with an internal cavity bridged by the headers, hence the name. The main advantage of this bond is economy in use of bricks, giving a wall of one-brick thickness with fewer bricks than a solid bond. The bond also gives the advantage that both skins are tied together.

7) Header Bond: All bricks are arranged in header courses. The following are some features of header
bond. This brick bond is used for curved surface in brick work because if stretcher is used for curved surface, it would project beyond the face of wall. All bricks are arranged in header courses.

Brick Work In Structures: 1) Brick Work In foundations: Brick work in foundation is done to transfer the load of super structure
to the ground. The width of the brick work in foundation is taken according to the load coming on it. The load of super structure is divided into various steps of brick works in foundation below plinth level. Care may be taken that all steps should accommodate in the ground.

2) Brick Work In Super Structures: Brick work in super structure transfer the load of RCC beam and
slabs to the foundation of the walls. Doors, windows and ventilators are accommodated in this part of brick work. This part of the building is used to divide the space into required room etc. Outer walls may be used for ornamental design of the building.

3) Brick Work in Parapet: Brick wall constructed on roof slab on terrace is called parapet walls.
Parapet walls are necessary to protect persons using terrace from falling. It is also necessary to construct

parapet wall for the safety of the joints of outer wall and RCC slab. It also adds to the beauty of the building.

Fig13. Parapet of a building

4) Brick Work in Partition Wall/ half brick wall: The partition walls are required to divide the space
according to the design. The thickness of these walls is 4.5 inches. Due to thin section of the wall the usable space is increased. As there is no load on these walls so they can be changed easily when any additional/alternation is required in the building. The cost of thin walls is less hence they are economical.

5) Brick Tiles Masonry: For enhancing the beauty of buildings, the exterior/exposed surface of wall is
constructed with the brick tiles according to the architectural drawings. For making this design brick tile masonry is done on required walls.

6) Brick Jali: Brick Jali is constructed to enhance the beauty of the building. In veranda brick Jali gives
extra air and light and protects from rain up to some extant. It saves the cost of the walls.

Fig14. Brick Jali

7) Brick Work in Arch: Arch is constructed to beautify the building. These are provided in openings to save the cost of RCC lintel.

Fig15. Brick Arch

8) Brick Work according to cement mortar ratio: 1. First class brick work in cement sand mortar 1:4: Brick walls constructed with cement sand
mortar 1:4 ratio means 1 part of cement and 4 parts of sand. This mortar is of high strength and is recommended for following construction works. Multi storey buildings Heavy weight /load bearing walls In earth quake zones Brick pillars Where there is more vibration due to heavy traffic or factory. Boundary wall, courtyard wall parapet wall and other free end walls Partition or 4.5 inch thick walls Brick works used for drainage

2. First Class Brick Work in cement sand mortar 1:6 :Brick walls constructed with cement sand
mortar 1:6 ratio means 1 part of cement and 6 parts of sand. This mortar is of medium strength and is recommended for following construction works. Three storey buildings Load bearing walls Heavy and frequent rainy zones Foundation of multi storey buildings

3. First Class Brick Work 1:7: Brick walls constructed with cement sand mortar in the ratio of 1:7
means 1 part of cement and 7 parts of sand. This mortar is low in strength and is recommended for following works. Toe walls Single storey buildings Temporary structures Light weight walls having no load of beams etc.

Common Defects in Brick Work:


Raw materials like brick, sand, cement and water are of sub standard quality without qualifying any test. Bricks are not soaked in water properly. The joints in brick works are thicker, unfilled properly. Raking of mortar is not done when the mortar is green. Bricks bats are used in masonry work. Mortar is not mixed properly on platform. There is improper mixing of cement mortar There is excessive water content in mortar Brick work is not in plumb, level and straight line. Mortar is not according to the structural requirements. There are gaps between door/window frame and masonry. The holes of scaffolding are not filled in with mortar properly. Vertical joints in brick work are hollow. There is high suction of brick and less water retention of mortar There are uneven joints in brick works There are voids in vertical joints There are disturbances of brick works just after the layout Over thick joints reducing the strength of brick work

Conclusion:
Brickwork is masonry produced by a bricklayer, using bricks and mortar to build up brick structures such as walls. Brickwork is also used to finish corners, door, and window openings, etc. in buildings made of other materials. Where the bricks are to remain fully visible, as opposed to being covered up by plaster or stucco, this is known as face-work or facing brickwork. Brickwork are mainly used in many structures like in foundation, roof, jali manufacturing, in art work, in masonry work and many other forms with the help or mortar. There is always some defects came when we are handling with the bricks and these are like bricks are not soaked with water properly, the joints in brick are thicker or unfilled or etc so we should always take care of common defects come in the brick structures so that our structure will have long life.

References:

1. 2. 3. 4. 5. 6. 7. 8. 9.

S.K.DUGGAL, Building Materials, New Age Publication http://goda02.com/brickwork-bonds http://www.diydata.com/techniques/brickwork/english/english.php http://poolandpatio.about.com/od/patioglossary/g/BrickBond.htm http://en.wikipedia.org/wiki/Brick http://en.wikipedia.org/wiki/Brickwork http://en.wikipedia.org/wiki/File:Flemish_Bond.jpg http://en.wikipedia.org/wiki/Zero-energy_building http://www.brickworkratings.com/

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