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    Assignment No 3 Materials

    Uploaded by

    Yasir Malikth
    1. The document summarizes the process of manufacturing bricks at a brick kiln in Pakistan. Soil is extracted and mixed with water to form clay. The clay is then molded into bricks and left to dry in the sun before being fired in a kiln. 2. There are several steps in the manufacturing process including mixing the soil and water, molding the bricks, drying them in the sun, transporting them to the kiln, and baking them at high temperatures. 3. The kiln produces around 28,000-30,000 bricks per day across 7 firing zones. Bricks are classified into different types and grades depending on their quality.

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    Assignment No 3 Materials

    Uploaded by

    Yasir Malikth
    35 views11 pages
    1. The document summarizes the process of manufacturing bricks at a brick kiln in Pakistan. Soil is extracted and mixed with water to form clay. The clay is then molded into bricks and left to dry in the sun before being fired in a kiln. 2. There are several steps in the manufacturing process including mixing the soil and water, molding the bricks, drying them in the sun, transporting them to the kiln, and baking them at high temperatures. 3. The kiln produces around 28,000-30,000 bricks per day across 7 firing zones. Bricks are classified into different types and grades depending on their quality.

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    Assignment No 3 materials

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    1. The document summarizes the process of manufacturing bricks at a brick kiln in Pakistan. Soil is extracted and mixed with water to form clay. The clay is then molded into bricks and left to dry in the sun before being fired in a kiln. 2. There are several steps in the manufacturing process including mixing the soil and water, molding the bricks, drying them in the sun, transporting them to the kiln, and baking them at high temperatures. 3. The kiln produces around 28,000-30,000 bricks per day across 7 firing zones. Bricks are classified into different types and grades depending on their quality.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    35 views11 pages

    Assignment No 3 Materials

    Uploaded by

    Yasir Malikth
    1. The document summarizes the process of manufacturing bricks at a brick kiln in Pakistan. Soil is extracted and mixed with water to form clay. The clay is then molded into bricks and left to dry in the sun before being fired in a kiln. 2. There are several steps in the manufacturing process including mixing the soil and water, molding the bricks, drying them in the sun, transporting them to the kiln, and baking them at high temperatures. 3. The kiln produces around 28,000-30,000 bricks per day across 7 firing zones. Bricks are classified into different types and grades depending on their quality.

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    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    of 11

    Assignment No: 03

    Visit to A Brick Kiln


    Introduction:

    We had an opportunity last weekend to visit a brick kiln names “Peshawar Bricks” situated
    in a village Bhalot, Thata Khalil, Taxila. It was near M-1 motorway and a cement factory. Our
    group expected the kiln near the near housing colonies, but it was situated at the place with no
    houses there, however, the kiln sat in the midst of the green fields, and some other kilns were
    also near it. We didn’t know much about them. Luckily, we went to a kiln that uses modern
    techniques for mixing soil to make clay for making bricks. The owner was requested to help us
    visit different places, and to show us, how they make bricks? He sent his brother as a guide for
    us to show us the methods and techniques they use for making bricks. The guide treated us in a
    very good way and his guidance was really appreciable. We met different people belonging to
    different areas of Pakistan. Most of them belonged to Pakhtun belt as the kiln was owned by a
    Pathan. The labors were working there on low wages even in the harsh weather conditions.
    Women were also working there as they were a cheap labor. We are thankful to them to help us
    complete a portion of our assignment.

    Process for Manufacturing:


    The bricks are passed through many processes before baking.
    1. Getting Soil and water
    2. Mixing to make clay
    3. Molding
    4. Sun Drying
    5. Transportation to brick kiln
    6. Baking in Kiln

     Getting Soil :

    First of all, the soil is extracted from nearby fertile land by using excavators and
    is collected using tractor and dumped to mixing machine by using trolleys.The
    clay obtained from different areas vary in composition which is identified by
    difference in colour,clays are thoroughly mixed before its addition to blending
    machine. The owner doesn’t allow to start the machine until 400 to 800 trips of
    the trolley’s soil is unloaded near the machine.
    Water Source

    The water is obtained by a nearby tank that is refilled by a bore or well. The
    tanker on the kiln is about 50 gallons and contains clean water for bricks
    manufacturing. Contaminated water is disposed to sanitary lines on daily basis.
    Blending machine which is about 500 meter away from water tank is attached to it
    through PVC pipes.The placemat of water tank at certain height makes it easy to
    transport water to blending machine.

     Mixing: (Machine Mixing)

    One tractor is used to start the machine which has shaft attached to it and the
    trolley is used to collect the freshly made clay from the machine. Mixing done by
    machine is uniform and led to achieve brick with better corner. This clay is then
    transported by using trolleys parked under the machine to the labors for molding
    purpose. It requires less labor for mixing and reduces time for making mud paste
    which in result led to increase per day production of kiln. Mixing using machines
    is a bit expensive for the owner as it utilizes a big amount of fuel for it, but it
    produces the best quality of bricks that has an effective strength.
     Molding:

    They are then molded by labors using a brick molder and are kept under sunlight
    for sun drying. After molding, the bricks are now under the responsibility of the
    owner. If the harsh weather such as rain destroys the bricks, it will be his loss, but
    the labors will get the cost for molding them.

    Molding of Bricks

    Dry bricks storage


    During the rainy season when it is not possible to mould the paste thus they stored
    dried bricks to bake them ,which does not affect their daily production.
     Sun Drying:

    After molding, the bricks are kept under sunlight for sun drying. Harsh weather
    conditions such as rain can destroy the bricks. It takes 7 to 8 days for bricks to dry
    in winter, and 3 to 4 days to dry in summer.

    Sun Drying
     Transportation to brick kiln:

    After sun drying, the bricks are then transported to brick kiln using horses,
    donkeys, and ponies as they are comparatively a cheap source.
    Bull’s Trench method

    Bull’s trench operation is used in kiln. Bricks are stacked in layers according to
    respective class as class A bricks require more heat so they are placed at the base
    and then further bricks are placed manual labor is used to stock them. its a
    continuous process in which un burnt bricks are stacked while burnt bricks are
    removed simultaneously.
     Baking:

    The bricks are then placed in the kiln accordingly; the baked bricks are put in
    front then partially baked, and at last freshly prepared bricks are placed. The coal
    is put in them to burn them. A flow of cool air is made to pass through baked
    bricks. The air becomes hotter while passing from baked bricks as they are hot
    making the partially baked bricks hot.

    It makes the freshly prepared bricks completely dry due to its heat. The air is then
    disposed through chimney. The coal is added with respect to time. A measureable
    quantity of coal is added in the kiln after every 15 minutes, and about 1 ton of
    coal is utilized each day at the kiln for baking the bricks.
    Kliner(Over burnt)

    In kiln due to excess heat some of the bricks are overburnt and become unsound
    as they changed their shapes and they are used for footings in buildings and
    readily available in kiln as by product.

    Baking in the Kiln

    Types of Bricks:
    On inspection, the guide told us that there were four different types of bricks available there i.e
     Type 1
     Type 2
     Type 3
     Clinker
    The samples were collected for different tests in Laboratory.

    Frog details:
    Frog is a depression made on the face of bricks during moulding.  Functions served by frog
    in bricks are: 
    The mortar accumulated in the frog forms a very good key for subsequent course of brick
    above it. 

    The frog of that bricks was also indented for makers/owners name. “Z” and “PR1” was
    written on them as “Z” stands for “Zahir Khan-the owner” and “PR1” stands for
    “Peshawar bricks- the name of the kiln”.
     Size:
    Standard size of clay brick is as follow:
    Length=8.75 inches

    Width= 4.25 inches


    Height=2.75 inches

     Strength:

     Production Capacity of the kiln:

    The kiln has a production capacity of about 28,000 to 30,000 bricks per day. On
    average, seven lands of the kiln are baked each day, and one land contains about
    4,200 baked bricks.

     Price of Bricks:

    The bricks were rated according to their class and size.

    1. First class bricks cost Rs. 8000 for 1000 bricks.


    2. Second class bricks cost Rs. 4000 for 1000 bricks.
    3. Third class bricks cost Rs. 6000 for 1000 bricks.
    4. Clinker costs Rs. 6500 for 1000 bricks.
    Decorative and Footpath Bricks
    Decorative ricks are also required for architectural and aesthetic purposes used on the buildings
    and walls. Whereas footpath bricks are used to make footpaths.

    The End

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