IS 2117 :1991

( Reaffirmed 1997 )
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Indian Standard
GUIDEFORMANUFACTUREOFHAND-MADE
COMMONBURNTXLAYBUILDINGBRICKS
( Third Revision /

UDC 691,421

@ BIS 1991

BUREAU OF IN-DIA-N STANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002

May 1991 Price Group 7

Clay Products for Buildings Sectional Committee, CED 30

FOREWORD

This Indian Standard ( Third Revision ) was adopted by the Bureau of Indian Standards, after the
draft finalized by the Clay Pcoducts for Buildings Sectional Committee had been approved by the Civil
Engineering Division Council.

Different practices for the manufacture of hand-made common bricks are adopted in different regions of
the country. It will be advantageous to give the existing knowledge and experience so far gained in the
form of guide in order to specify the minimum requirements for various manufacturing operations.

In brick industry all operations, such as preparation of clay, moulding, drying and firing are carried out in
the open. The kiln most commonly used is the bull’s trench. The design and construction of such a kiln of
optimum capacity has been covered in IS 4805 : 1978. This standard has been prepared to furnish general
guidance in the selection of raw materials and the processes of manufacture of hand-moulded bricks ( from
clay-alluvial and black cotton ).

Bricks may be made from a mixture of plastic clays and fly ash from thermal power stations. However,
as the composition of these material varies over a wide range it is necessary to determine a suitable batch
composition after laboratory tests. Two materials may be mixed wet either manually or in a machine. The
processes of moulding, drying and firing are similar to those described in this standard.
This standard was first published in 1963 and revised in 1967 and 1975. This revision has been prepared
to include such of’ the data which have been established since it was last revised, like manufacturing bricks
with various additives like fly ash, sandy loam, rice husk ash, basalt stone dust and details of firing process
besides making other contents up to date.
 lS 2117 : 1991

Indian Standard
GUIDEFORMANUFACTUREOFHAND-MADE
COMMON BURNT-CLAY BUILDINGBRICKS
(Third Revision J
1 SCOPE Clay 20 to 30 percent by mass
Silt 20 to 35 percent by mass
The standard covers the selection of site, raw
materials, method of moulding and burning ~of Sand 35 to 50 percent by mass
hand-made common burnt-clay building bricks.
5.1.2 The total content of clay -and silt may pre-
2 REFERENCES ferably be not less than 50 percent by mass.
The Indian Standard listed in Annex A are neces-
NOTE - The limits for particle size grading specified
sary adjuncts to this standard. above are not applicable to black cotton soil and lateri-
tic soils.
3 TERMNOLOGY
For the purpose of this standard, definitions given
5.1.2.1 The total lime ( CaO ) and magnesia
in IS 2248 : 1981 shall apply. ( MgO ) (see IS 1727 : 1967 ) in the case of
alluvial soil will be not more than one
4 SELECTION OF SITE FOR THE MANU- percent and in other cases shall not preferably be
FACTURE OF HAND-MADE COMMON more than 15 percent. The lime shall be in finely
divided form. The total water soluble material
BURNT-CLAY BUILDlNG BRICKS
shall not be more than one percent by mass [ see
4.1 The site should be selected after giving due IS 2720 (Part 21 ) : 1977 1.
consideration to the suitability of soil and the
location of water-table. NOTE - The data for the chemical and mineralogical
composition of the soil as raw material for the manu-
NOTE - It is a good practice to select a site where the facture of building bricks are not yet conclusively
water-table during burning season remains at least established.
about 2 metres below kiln floor.
5.1.2.2 The chemical analysis of the soil shall be
4.2 The site should be located in conformity with made in accordance with IS 1727 : 1967 and
the prevailing town planning regulations or other IS 2720 ( Part 21 ) : 1977.
bye-laws of similar nature, particularly in view of
the smoke of the kiln which may prove a 5.1.3 The plastic properties of the clay shall be
nuisance. determined by finding the plasticity index by the
method given in IS 2720 ( Part 5 ) : 1985. Tht
4.3 The availability of suitable clay conforming to
range of plasticity index shall be 15 to 25.
the requirements laid down in 5, within an econo-
mical distance, will be an important factor 5.1.3.1 For quick field observations and intermit-
influencing the location of the kiln; greater consi- tent checks, sample tests as given in Annex B may
deration shall, however, be given to the distance be found useful.
of the distribution centre of the finished bricks
rather than only to availability of the raw mate- 5.2 Additives
rials from the source, as otherwise it may prove
more costly to arrange the distribution and des- Certain additives such as fly ash, sandy loam.
patch of finished bricks. rice husk ash, basalt stone dust, etc are ofterA
required not only to modify the shaping, drying
4.4 The nearness to a rail head or transport and firing behaviour of clay mass but helps in
facilities through road or water shall be important the conservation of agricultural land and utilisa-
considerations in the final selection of a kiln. tion of waste materials available in large quanti-
ties. These additives should, however, have a
5 SELECTION OF RAW MATERIALS desirable level of physical and chemical charater-
5.1 Selection of Clay istics so as to modify the behaviour of clay mass
within the optimum range without any adverse
5.1.1 The clay or mixture of clays selected should effect on the performance and durability of bricks.
preferably conform to the following mechanical Some of the basic physico-chemical requirements
composition: of conventional additives are as under:

1
IS 2117 : 1991

5.2.1 Fly Ash 5.2.4 Basalt Stone Dust

5.2.1.1 Fly ash is a waste material available in Basalt stone occurs underneath the black cotton
large quantities from thermal power plants and soil and its dust is a waste material available in
can be mixed to the brick earths as alluvial, red, large quantities from stone crushers. The finer
black, marine clays, etc used for brick making. fraction from basalt stone crushing units can suir-
The Indian fly ash contains amorphous glassy ’ ably be mixed with soil mass to modify the
material, mullite, haematite, magnetite, etc and shaping, drying and firing behaviour of bricks.
shows a chemical composition similar to brick The dust recommended for use as an additive with
earths. These silicates also help towards strength brick earth should be fine ( passing 1 mm screen j
development in clay bodies on firing, when mixed free from coarse materials or mica flakes and
in optimum proportion depending on the physico- should be of non-calcitic or dolomitic origin.
chemical and plastic properties of soils to be used
for brick making. The proportion of fly ash mixed 6 PREPARATION OF CLAY ( ALLUVIAL )
CLAY ADMIXTURES
as an additive to the brick earth should be opti-
mum to reduce drying shrinkage, check drying 6.0 The soil used for making building bricks
losses and to develop strength on firing w:thout should be processed so as to be free from gravel,
bloating or black coring in fired product. The coarse sand ( practical size more than 2 mm )
crystallites present in the fly ash should comply lime and kanker particles, vegetable matter, etc.
with the resultant high temperature phases in the 6.1 Requisite predetermined proportions of addi-
finished product. tives such as fly ash, sandy loam, rice husk ash,
5.2.1.2 The desirable characteristics of fly ash stone dust, etc as indicated above should be spread
which could be used as an additive to the soil over the plain ground surface on volume bas:s.
mass are given in Table 1. The soil mass is then manually excavated,
puddled, watered and left over for weathering and
subsequent processing.
Table 1 Desirable Characteristics of
Fly Ash for Use as an Admixture with 6.2 Weathering
Brick Earths
The soil should be left in heaps and exposed to
weather as long as possible and for eat least one
Sl No. Characteristics Desired Level month in cases where such weathering is consi-
dered necessary for the soil. This is done to
(1) (2) (3) develop a homogeneity in the mass of soils, parti-
i) Texture Fine, 2 000 to 3 000 ems/g cularly if they are from different sources, and
ii) Coarse material 0’5 percent also to eliminate the impurities which get oxidized.
(+lmm),Mex Soluble salts in the clay would also be washed off
iii) Unburnt carbon per- 15 percent by rain to some extent ~by this, which otherwise,
cent by mass, Max may cause scumming at the time of burning the
bricks in the kiln. The soil should be turned over
iv) Water soluble per- 0’ 1 percent
cent by mass, Max at least twice and it should be ensured that the
entire soil is wet throughout the period of
weathering.
5.2.2 Sandy Loam NOTE - In order to keep the soil wet, water may be
sprayed as often’as necessary.
Addition of sandy loam is often found effective in
controlling the drying behaviour of highly plastic 6.3 Tampering
soil mass containing expanding group of clay
6.3.1 Addition of water to the soil at the dumps
minerals. Sandy loam should preferably have
is necessary for the easy mixing and workability,
mechanical composition as under:
but the addition of water should be controlled in
Clay ( 2 micron 8- 10 percent such a way that it may not create problem in
Silt Z-20 micron 30-50 percent moulding and drying. Excessive moisture content
Sand P 20 micron 40-60 percent may affect the size and shape of the finished brick.
The tempering of the clay should preferably be
The material should, however, meet the other carried out by storing the soil in a cool place in
requirements as specified under 5.0. layers of about 30 cm thick for not less than
36 hours. This will produce homogeneity in the
5.2.3 Rice Husk Ash mass of clay for subsequent processing.
The ash should preferably having unburnt carbon 6.3.2 After weathering, the required quantity of
content in the range of 3-5 percent ( determined water should be mixed with the soils so as to
as LO1 ) and free from extraneous material can obtain the right consistency for moulding. Addi-
be used with plastic black and red soils showing tions of sand and other materials, if necessary,
excessive shrinkages. may also be made at this stage to modify the

2
 IS 2117 : I991

composition of the soil. The quantity of water 8 MOULDING

may range from l/4 to l/3 by mass of the soil,
sandy soils requiring less water and clayey soils 8.1 Design and Construction of the Brick
more water. Nature and degree of wetness of the Mould
soil at the stage of water addition shall also be
duly considered in this respect and the observa- 8.1.1 The mould should be constructed prefera-
tions made in preliminary test ( see 5.1.3.1 ) may bly of metal. Seasoned wood with or without
be useful for the judgement. The moistened soil sheet metal lining may also be used ( see Fig. 1 ).
may be kneaded with spades or other manual or The thickness of the sides of the mould shall be
mechanical equipment into a plastic mass. not less than 3 mmif of metal, and not less than
10 mm if of wood.
6.3.3 After addition of water and kneading, the
soil may be pugged in a pug-mill of suitable size 8.1.2 The inner faces of the mould shall be
corresponding to the quantity of production of smooth. All angles between adjacent intetiior faces
bricks. The pug-mill may be mechanically opera- of the mould as assembled should be 90’ f 0.5”.
ted or may be a simple animal driven type.
Salient features of the simple design of a pug-mill 8.1.3 The base of the mould should have a pro-
are given in Annex C. The plastic mass as given jection corresponding to the frog of the brick a?.
in 6.3.1 will be conveyed and fed into the pug. shown in Fig. 1.
mill, and the tempered soil issuing from the pug.
8.1.4 The size of the mould may incorporate due
mill will be collected for moulding operations.
allowance for the total linear shrinkage of the
6.4 Mixing moulded brick on drying and burning as showrl
in Fig. 1, so as to obtain the specified size for the
Two or more soils may have to be mixed so as to
finished product. Gang moulds suitable for
conform to the requirements of clay as laid down
moulding a number of bricks at a time may also
in 5.1.1. The mixing may be done in a vat, before
or in the pug-mill described in be employed.
tempering
Annex C. NOTE - Values of the allowance for shrinkage n L,
n B, A H, A D, A X, A Y, etc as percentage of tht
7 PREPARATiON OF CLAY TBLACK) corresponding dimensions of the finished brick and frog,
COTTON AND ALLIED will depend not only upon the nature of raw material
but also on auantitv of water added in the mouldinr
7.0 In the areas where black cotton soils occur, and buildmgoperations. iSormalIy total linear shrinkagts
a more elaborate method* of processing as given allowance ( inclusive of firing shrinkage ) will vat-v
in 7.1 shall be followed. between 8 and 15 percent. Foriarge scale production it
is recommended that before finalizing the mould size,
7.1 The clay, which may be black or a mixture experimental lots of bricks will be actually burnt in thr,
-of black and yellow, is first washed free of the kiln and a statistical analysis made for the size of bricks
lime kanker in the ‘ GHOL ’ tanks. The slurry is produced and the mould size will be adjusted accord-
then run off to the settling tanks. After 3-4 days, ingly.
when the clay has settled down, the supernatant 8;2 Moulding Procedure
water is bucketed off. Opening material like
powdered grog of fine coal ash ( passing 200 mm- 8.2.1 Hand-made bricks may be either ground.
IS Sieve), which opens up the texture of clay moulded or table-moulded. A level, firm surface
mass, is then added in predetermined proportions. of ground, will be used in the former case. Typica!
This is usually 30 to 40 percent of the mass of specification for accessories for table moulding are
clay. A solution of 0.5 percent sodium chloride given in Annex D.
may also be added at this stage to prevent lime
8.2.2 Before moulding, the inside of the mould
bursting, The clay is then thoroughly mixed with
will be cleaned and then sprinkled with sand or
the opening material added and allowed to dry
ash. If slop moulding is adopted the mould should
further for a period of 3-4 days till the mix
be dipped in water and cleaned. The mould will
attains the correct moulding consistency.
then be set firnily on the level surface.
7.~1 Preflaration of Grog
8.2.3 A quantity of clay slightly more than the
Grog is prepared by lightly calcining lumps of
volume ot‘ the mould, should be taken, rolled in
black cotton soil (about 10 to 15 cm dia) in a
sand, if found necessary, then shaped suitably
clamp at about 700 to 750°C. Coal ash, fire wood,
into a single lump and dashed firmly into the
brambles, etc, may be used as fuel. The fuel
mould with a force ( that is to be judged by the
and clay lumps are arranged in alternate layers
moulder by experience ) SO that the clay comple-
in the clamp. After calcination, the clay is pulveri-
tely occupies the mould ~without air pockets and
zed in a machine, such as a disintegrator, a
with the minimum surplus for removal.
hammer mill or a pan-mill, to a fineness of less
than 2.0 mm. 8.2.4 The surplus clay should be scraped off with
-----:---- a sharp straight edge or a stretched wire and the
* A detaIled layout of the processing plant may be obtain-
ed from Central Building Research Institute, Roorkee. top surface levelled.

3
IS 2117 : 1991

,,-0430mm THICK
, MS 'MEET LINING

/e---X+AX -----w Y+AY--j---P-

SECTION AA SECTION BB

FIG. 1 DETAILS OF MOULD

8.3 The whole assembly of mould should then be 8.4.4 The surplus clay is removed off with a sharp
lifted, given a slight jerk, and inverted to release straight edge or a stretched wire and top surface
the moulded brick on a pallet board in rhe case levelled.
of table moulding or on dry level surface of the
ground in the case of ground moulding. The 8.4.5 The shaped brick is thenejected by pressing
ground may be advantageously sprinkled with down the pedal when the loose bottom steel plate
sand before releasing the brick over it, so that the alongwith the shaped brick is lifted out of the
brick does not stick to the ground. mould. A wood plank of similar size as that of a
brick is placed over the shaped brick and is
8.4 Operation of Brick Moulding Table manually lifted along with the loose base plate.

8.4.1 Alternatively, an improved hand moulding 8.4.6 The pedal is then released and the base
table for shaping building bricks may be used. plate drops to its original position.
Details of the same are given in Annex E. 8.4.7 The moulded brick is then turned on the
side, over the wooden pallet. Both the plates
8.4.2 For moulding bricks, clay is mixed with
loosely adhering to the brick surface are gently
water and kneaded in the same manner as detailed
removed. The base plate is returned to the mould
under 6.0 and 7.0. The consistency of rhe clay
box for subsequent shaping of other bricks from
should be plastic and preferably be kept margi-
the brick moulding table.
nally stiff.
8.4.8 Another wooden pallet is then placed on
8.4.3 At the moulding table a quantity of clay is -the top face of the brick which is then carried
rolled into clots slightly larger in volume than away to the drying ground where it is placed on
the~mould. The clot is then rolled over fine sand edge to dry.
and thrown with little force into the mould so that
the clay completely occupies the mould without 9 DRYlNG
air pockets and with minimum surplus for
removal. 9.1 The moulded brick should be allowed to dry
to an approximate moisture content of 5 to 7
NOTE - Before throwing the clot into the mould. the percent. The recommended method of drying is
inside of the mould should he cleaned and then sprink- shown in Fig. 2.
led with sand or ash. However, in case of highly sticky
or plastic soil mix, the inner side of the mould may be 9.1.1 It may be noted that all the channels in the
wiped off with wet or oily rag for easy demoulding.
This may be done whenever necessary, and preferably, longitudinal and transverse directions are cross
after shaping 4 or 5 bricks from the mould. ventilated.

3
 IS 2117 t 1991

COURSES 1,3,5,7, ETC

COURSES 2 , 4 9 6 * 8 9 ETC

FIG. 2 METHOD OF DRYING OF BRICKS

9.2 As far as possible the moulded bricks should 11.2 The moulded bricks should be set in a
be protected effectively against rain and dampness uniform pattern in the kiln with trace holes, fuel
till they are stacked inside the kiln. shafts, flues, etc, in accordance with the design of
i0 HANDLING AND TRANSPORT OF kiln. While arranging the bricks a minimum
MOULDED BRICKS space of 10 mm shall be given between adjacent
bricks in the header and stretcher courses.
10.1 During conveyance to the kiln, the moulded
bricks should be loaded or unloaded one by one. 11.2.1 In the fuel shaft, bricks, should be suitably
arranged to project in such a manner so as to
11 SETTING BRICKS IN THE KILN form a series of ledges on which the fuel could
11.1 Pattern of setting of bricks in bull’s trench rest and burn, with only a small portion falling
kilns is shown in Fig. 3A. The details of brick direct to the floor of the kiln.
setting based on 24 brick length* is shown in Fig.
3B. The pattern of setting shown in this figure is 11.3 The top two courses of KACHCHA bricks in
for coal firing. The pattern shall be slightly diffe- the kiln, should be set as close as possible with
rent for wood firing. little or no spacing between them so as to form a
complete roof covering for the kiln-setting. Holes
*Detailed drawings for other brick lengths are available of size not less than 100 x 100 mm shall be left
at Central Building Research Institute, Roorkee. in the roof for feed of fuel into the fuel shafts.

5
IS 2117 : 1991

11.4 The top of the setting excluding portions are provided on this space ( see Fig. 5 ), the actual
occupied by feed holes should be covered with a number depending on the width of the trench.
fine ash about 200 mm thick. The feed holes
12.2 Initially log wood ( 100 to 150 mm dia and
should be tightly closed with cast iron pot and
1.5 to 2 m long ) soaked in kerosene oil is fed
caps.
through the top feed holes over the temporary
11.5 After every second chamber a gap of about wall and are ignited by introducing lighted rags
120 mm should be left for inserting the sheet iron through the air holes at the bottom. Feeding of
cross dampers along the entire width of the fire woodris continued at 20-30 min intervals, the
chamber. holes being kept closed by metallic caps between
the feeds. The red hot charcoal that collects on
11.6 The wicket opening to chambers should be the floor must be pushed forward through the
sealed by temporary cavity walls. The cavity trace holes in the setting by long iron packers
( about 50 mm width ) may be filled with fine kiln ( about 3 m long ). The chimneys should be ob-
ash and the outside of the walls -may be plastered served for formation of dense black smoke which
over with a thick layer of mud. should not persist for more than ~3 to 4 min after
each feed. Observation should also be made of
12 INLTIATiON OF FIRE the condition of the fire and the movement of
12.1 Firing may be started after nearly three- flames and hot gases through the brick setting to
fourth of the trench has been loaded. The get an idea of the draught If draught appears to
chimneys may be positioned about 5.5 to 6 0 m be slack, the chimneysmay be heated up by light-
away from the first row of feed holes. When start- ing small fires at the chimney bases ( externally ).
ing the fire, a temporary cross wall, one-brick 12.3 After about 10 to 12 hours of firing the kiln
thick, is constructed at a distance of 250 mm from floor and the bricks in the first row of columns
the first row of brick columns, A number of air should be heated to red heat ( that is 750 to
holes ( 100 x 100 mm ) ( see Fig. 4 ) are left at 800°C ) and feeding of black coal in the first row
the foot of this wall. The top opening between of feed holes in the main setting started. Within
this wall and the main setting is closed up bv 5 to 6 hours after this a good bottom heat in the
projecting bricks from either side and the usual furance beyond the first row of feed holes should
cover of ash is laid on. A number of feed-holes be obtained. Feeding in all the feed holes in the

FEED HOLES
Ii-

LKILN WALL
3A General Arrangements
-FIG. 3 PATTERNOF SETTINGOF BRICKS IN KILN - Contd

6
 IS 2117 : 1991

rFEE0 tiCtEST r ASH LAYER

I-- 2ee-l
bdmml
49d+-

ENLARGED SECTION AA ENLARGED SECTION BB

36 Details of Brick Setting Based on 23 Brick Length
All dimensionsin millimetres.
FIG. 3 PATTERNOF SETTING OF BRICKS IN KILN

FEED HOLES

DP OF SETTING

FIG. 4 LAYOUT OF AIR HOLES IN BRICK KILN

7
3S 2117 : 1991

temporary wall as well as the first row of columns The schedule of firing may, however, vary accord--
should be continued till sufficient bottom heat is ing to the requirements of a kiln firing a particular
built up. clay using a particular type of coal. It will also
12.4 When a sufficiently strong draught has been vary if coal ash or fly ash containing a certain
built up, the chimney may be advanced by 5 to amount of unburnt carbon, is admixed with the
6 m and the position of the cross damper readjus- clay.
ted. Thus within 24 to 30 h the kiln should be
brought up to full firing order. Firing in the feed 13.1.1 Bituminous slack coal Grade I should
holes of the temporary wall should be continued preferably be used for firing brick.
till the fire has advanced by at least 10 to 12 m and 13.1.2 When advancing the fire, a fresh row
the bricks in the first row have been fully burnt. should be opened only when the temperature at
The temporary wall can be pulled down only the base of the setting or on the kiln floor has
after the fire has gone round the curved part of reached at least 750°C. This is indicated by the
the trench and the bricks in the first row have appearance of a dull red glow. Initially small
cooled down sufficiently to permit unloading to quantities of coal, say, 260 to 500 g should be fed
start. at a time in each feed hole; the amount of feed
13 CONTROL OF BURNING should be raised gradually to 1 to 2 kg/feed-hole
as the temperature rises. After each feed the
13.1 Schedule of Firing
feed-hole caps should be tightly replaced to pre-
In a large capacity kiln, there are normally 30 vent in-leakage of cold air. While feeding fuel,.
chambers ( see IS 4805 : 1978 ). When the kiln loose ash from the top covering should not be
has been brought up to the regular firing order, allowed to drop into the feed hole.
the schedule of firing that should generally be
maintained is indicated below: 13.2 The temperature at which bricks are to be
Loading 1 chamber fired may range from 900 to 1 000°C depending
3,
Unloading upon the type of clay. The temperature may be
; ,,
Firing observed by means of suitable temperature
3,
Preheat measuring devices, and the fuel feed and draught
Cooling 2: ” adjusted for control.
,,
Empty 4
NOTE-Either a pyrometer or pyrometric cones.
30 whichever is suitable may be used for the measurement
of temperature.
CROSS DAMPER FEED HOLES CHIMNEY

TRENCH WIDTH

FIG. 5 PLAN SHOWING DETAILS OF FEED HOLES A-NDTEMPORARY WALL FOR INITIATING FIRE
8
 1s 2117 : 1991

13.2.1 The rate of fire travel should generally be 13.5 Cooling

not less than 5 m/24 h. Operation of dampers,
Cooling of the brick in the kiln should be gra-
setting of bricks and emptying of bricks will keep
dual. Normally about 15 to -20 chambers are
pace with the advancing fire cycle.
ma.intained in the cooling zone.

13.3 There are five distinct stages in the firing 14 UNLOADING OF BRICKS FROM THE
cycle, such as (a) smoking, (b) pre-heating, (c) KILN, SORTING AND STACKING
firing, (d) soaking, and (e) cooling, to which 14.1 The bricks should be unloaded from the
the bricks in the kiln should be subjected to. kiln and conveyed to the sorting area with mini-
The proper and efficient control of these stages mum breakage.
greatly depend upon the technique and experience
14.1.1 In the case of bricks made from clays
of the burner.
containing lime kanker, the bricks in stack
should be thoroughly soaked in water (docked)
13.4 Under normal conditions, the pair of to prevent lime bursting.
chimneys are maintained at a distance of 10 to 14.2 The bricks should be sorted out into the
15 m from the first row under fire, and are various classes.
shifted once every 12 hours. However, if any
combustible matter has been mixed with the clay 14.3 Bricks, which remain underburnt may be
then the chimneys should be maintained at a stacked along the walls of freshly loaded~cham-
,distance of 20 m or so. bers.
14.4 For proper inspection of the quality and
13.4.1 The draught of the kiln should be obser- count of bricks, they may be arranged m stacks on
ved by suitable draught gauges at the base of dry surface, the stacks being two-brick thick up
chimney and should be adjusted by operating to ten-course high and up to hundred-brick long
the temperature as specified by the designer of and the distance between two adjacent stacks
.-the kiln. being not less than 0 8 m.

ANNEX A
(Clause 2.1 )

LIST OF REFERRED INDIAN STANDARDS

IS No. Title JS flo. Title

1727 : 1967 Methods of test for pozzolanic 2720 Methods of test for soils:
materials ( jirst revision ) (Part 5) : 1985 Determination of liquid and
plastic limits ( second revision )
(Part 21) : 1977 Determination of total soluble
solids ( jrst revision )
‘2218 : 1981 Glossary of terms relating to clay
products for building (jrst revision) 4805 : 1978 Guide for construction of
brick kiln ( jht revision )

ANN-EX I&
( Clause 5.1.3.1 )

FIELD TESTS FOR SOIL FOR BRICKS MANUFACTURE

B-l TESTING SOIL FOR DRYING B-l.3 Keep the ball in the sun for drying.
SHRINKAGE When dried, examine the ball for loss of shape
and surface cracks, if any.
B-l.1 The soil should be ground to a fine
power and mixed with sufficient water, added in B-l.4 Conclusions
small quantities, The mix should then be kneat-
ed into a plastic mass of the required B-1.4.1 If the ball has deformed on drying
consistency. and crumbles easily when pressed lightly, it may
be inferred that sand content is excessive.
B-1.2 Take a handful of the soil prepared as
in B-l.1 and -form into a ball of about 80 mm B-1.4.2 If the ball is hard but shows cracks on
-diameter. the surface, then the sand content is insufficient.

9
B-l.5 If the soil is not found suitable as inferred B-2.2 Bricks of standard size should be actually
in B-1.4, the test should be repeated after modi- moulded from the soil as prepared in B-2.1 and
fying the composition of the soil, such as by examined for sharpness of edges and corners in
mixing different proportions of two soils or by green condition.
addition of sand, etc, for checking the suitability.
B-2 TESTING SOIL MOULDING B-2.3 If edges and corners are not sharp, the
CHARACTERISTCS test should be repeated varying the quantity of
water added, so that finally _a satisfactory result
B-2.1 A quantity of soil as adjusted for composi- is obtained.
tion should be taken and water should be added
in just enough quantities and the mix kneaded
well so as to attain a plastic consistency at which B-2.4 The moulded bricks should be left to dry
it is possible to roll threads of about 3 mm out four days in the sun and examined for shrinkage
of the soil. cracks.

ANNEX C
( CZauses6.3.3 and 6 4 )

SALIENT FEATURES OF A SIMPLE TYPE OF ANIMAL DRIVEN PUG-MILL

C-l SALIENT FEATURES being worked. The knives at the top and bottom
are such that they exert in addition to cutting a
C-l.1 The pug-mill ( see Fig. 6 ) consists of a downward force on the clay during rotation.
conical tub made of strong timber or iron, typical Cross knives may also be fitted to the middle
dimensions being 1 to 1.8 m high, and 1 to I *2 m horizontal knives for cutting through and break-
~diameter at top. The tub is fitted in the centre ing all clay lumps. There is a square or rectan-
with a revolving upright, iron shaft carrying gular opening at the bottom as shown in Fig. 6,
horizontal knives, the shape and inclination of through which the pugged clay will be forced
which may be as required for the type of soil out.

f!l rSHAFT

L OPENING

FIG. 6 DETAILSOFPUG-MILL

10
 IS 2117 : 1991

ANNEX D
( Clause 8.2.1 )

TYPICAL SPECIFICATIONS FOR ACCESSORIES FOR MOULDING TABLE

D-l MOULDING TABLE The stock board is provided with four pins one
at each corner of the bottom side, which when
D-l.1 The moulding table is 1.2 to 1.8 m long fitted into corresponding holes on the moulding
and O-6 to 1-O m wide, and made of wood or table hold the board tightly in position during
iron ( see Fig. 7 ). moulding. The stock board also has a projection
D-1.2 It is smoothly finished at top and suppor- at the top so as to form the frog of the brick
ted horizontaliy at a height of 1 to 1.2 m. The being moulded ( see Fig. 8 ).
table also has holes to accommodate accurately,
D-3 PALLET BOARDS
the bottom pins of the stock board ( see D-2 ).
D-3.1 These are rectangular pieces of wood of
D-2 STOCK BOARD
size 30 cm x 15 cm and 10 mm thick with
D-2.1 A wooden board has iron lining around smooth surface on one side. The pallet boards
the upper edge and with such dimensions as to are used conveying for the moulded bricks in the
fit accurately but loosely the interior of the mould drying yard ( see Fig. 7 ).

rWATER CONTAINER
MOULDER’S SAND-, /
-STOCK-BOARD
PALLETTES IN PRO
POSiT!ON FOR USE PUGGED CLAY

CLOT MOULDER’S PLACE

CLOT MOULDER’S SAND

MOULDER’S PLACE

i TAKING-OFF PLACE
FIG. 7 DETAILSOF MOULDING TABLE

/-PROJECTION
FOR FROG

FIG. 8 DBTA~LSOF STOCKBOARD

11
IS 2117 : 1991

+NNEX E
( Clause 8.4.1
)
IMPROVED BRICK MOULDING TABLE

E-l DESIGN AND CONSTRUCTION OF E-2 The inner faces of the mould shall be
BRICK MOULDING TABLE smooth. All angles between adjacent interior
faces of the mould as assembled should be 90”’
E-l.1 Various parts of the moulding table are
f 0.5”.
~shown in Fig. 9. The brick moulding table
essentially consists of a wooden table to which a E-2.1 The frog shall be fixed to the base plate
metallic mould is fixed. The mould is provided immediately above which a false bottom plate
with a movable mild steel bottom plate attached with its centre cut out to accommodate the frog
to a vertical ejector system. The vertical shaft is is loosely fitted.
actuated by a foot lever mechanism. Two guide
rollers are provided for the smooth vertical E-2.2 The size of the mould may incorporate due
movement of the shaft. On releasing the pedal, allowance for the total linear shrinkage of the
the base plate drops down ~to rest on four corner moulded bricks on drying and burning so as to
blocks, the position of which is also adjustable. obtain the specified size of the finished brick.

,CLAY MASS
MOULDING TABLE

%$-VERTICAL SHAFT I
ROLLERS

DETAILS AT A-A

FIG. 9 IMPROVEDBRICK MOULDING TABLE ( ASSEMBLYDRAWING) - Contd

12
 IS 2117 : 1991

WOODEN SCREW

SECTIONAL ELEVATION SECTION AT A-A

Sl No. Legend Material Sl No. Legend Material

1 1 Table Wood 6 Foot Lever MS.

2 I Brick Mould M.S. 7 Frog Wood

3 ~ Ejector M.S. 8 Flange M.S.

Angle Iron
\
4 ~ Ejector Top Plate M.S. 9 Ejector Support M.S.

5 ’ Lever Guide M.S. ’ 10 Loose Plate M.S.

5A Angle Iron MS. 11 Roller M.S. 2 Nos.

-

.411 dimensions in millimetrs.

FIG 9 IMPROVED BRICK MOULDING TABLE

13
Standard Mark
The use of the Standard Mark is governed by the provisions of the Bureau of Indian Standards
Act, 1986 and the Rules and Regulations made thereunder. The Standard Mark on products
covered by an Indian Standard conveys the assurance that they have been produced to comply
with the requirements of that standard under a well defined system of inspection, testing and
quality control which is devised and supervised by BIS and operated by the producer. Standard
marked products are also continuously checked by BIS for conformity to that standard as a
further safeguard, Details of conditions under which a licence for the use of the Standard Mark
may be granted to manufacturers or producers may be obtained from the Bureau of
Indian Standards.
Btweau _of Indian Standard*

BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to promote
harmonious development of the activities of standardization, marking and quality certification of goods
and attending to connected matters in the country.

Copyright

BIS has the copyright of all its publications. No part of these publications may be reproduced in any form
without the prior permission in writing of BIS. This does not preclude the free use, in the course of
implementing thestandard, of necessary details, such as symbols and sizes, type or grade designations.
Enquiries relating to copyright be addressed to the Director ( Publications ), BIS.

Revision of Indian Standards

Indian Standards are reviewed periodically and revised, when necessary and amendments, if any, are
issued from time to time. Users of Indian Standards should ascertain that they are in possession of the
latest amendments or edition. Comments on this Indian Standard may be sent to BIS giving the
following reference:

Dot : No. CED 30 (4759)

Amendments Issued Since Publication

Amend No. Date of Issue Text Affected

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