CLAY PRODUCTS

•Clay products employed in building

industry.
I. Tiles
II. Terracotta
III. Earthenware
IV. Stoneware
V. Porcelain
VI. Bricks
 Introduction

•A ceramic is an inorganic, non-

metallic solid prepared by the action
of heat and subsequent cooling.
•Ceramic materials may have a crystalline or
partly crystalline structure, or may
be amorphous (e.g., a glass).
•Ceramics now include domestic, industrial
and building products and a wide range
of ceramic art.
The earliest ceramics
made by humans
were pottery objects,
made from clay, either
by itself or mixed with
other materials,
hardened in fire. Later
ceramics
were glazed and fired
to create a colored,
smooth surface.

A Ming Dynasty porcelain vase

dated to 1403–1424
This category of materials includes things like tile, bricks,
plates, glass, and toilets.
CERAMIC TILES
PROPERTIES

•They are hard and brittle

•Strong in compression
•Weak in shearing and tension
•Withstands chemical erosion due to acidic or
caustic environments
•Withstands high temperatures
Clay products employed in building
industry.
 TERRACOTTA

• a type of earthenware , is a clay-based unglazed or

glazed ceramic, where the fired body is porous.
• Its uses include vessels (notably flower pots), water and waste water
pipes, bricks, and surface embellishment in building construction, along
with sculpture such as the Terracotta Army and Greek terracotta
figurines.
• The term is also used to refer to items made out of this material and to
its natural, brownish orange color, which varies
Terracotta designs
outside the Kantajew
Temple, Dinajpur,
Bangladesh
Characteristics of Terra cotta
• - Fired clay

• - Typically hollow, formed by pressing clay into a mould, by

• hollowing out portions of a solid, or by extruding it.

• - Usually low-fired

• - Typically a reddish, unglazed ceramic material. It may also

• be a hard-fired glazed or unglazed ceramic material.

• - Durable (dependent upon the degree of firing)

• - Fireproof

• - Strong
 Types of Terra cotta:

•Brownstone terra cotta

• Fireproof construction terra cotta
• Ceramic veneer terra cotta
• Glazed architectural terra cotta
Glazed architectural terra cotta
Ceramic veneer terra cotta
Fireproof construction terra cotta
Brownstone terra cotta
TYPICAL USES

Typical historical uses for terra cotta included:

- Sculpture

- Unglazed units used for structural purposes

- Glazed units for building exteriors

STONEWARE

• Stoneware is a vitreous or semi-vitreous ceramic

made primarily from stoneware clay or non-
refractory fire clay.
• Stoneware is fired at high temperatures.
• It is nonporous and so does not need a glaze
TYPES OF STONE WARE

• Traditional stoneware
• Fine stoneware
• Chemical stoneware
• Thermal shock resistant stoneware
• Electrical stoneware
• Traditional stoneware - a dense and inexpensive body. It is opaque, can be
of any colour and breaks with a conchoidal or stony fracture. Traditionally
made of fine-grained secondary, plastic clays which can used to shape
very large pieces.
• Fine stoneware - made from more carefully selected, prepared, and
blended raw materials. It is used to produce tableware and art ware.
• Chemical stoneware - used in the chemical industry, and when resistance
to chemical attack is needed. Purer raw materials are used than for other
stoneware bodies. Ali Baba is a popular name for a large chemical
stoneware jars of up to 5,000 litres capacity used to store acids.
• Thermal shock resistant stoneware – has additions of certain materials to
enhance the thermal shock resistance of the fired body.
• Electrical stoneware - historically used for electrical insulators, although it
has been replaced by electrical porcelain.
STONE WARE IN ARCHITECTURE
 TILES :
• A tile is a manufactured piece of hard-wearing
material such as ceramic, stone, or even glass.

• Tiles are generally used for

covering roofs, floors, walls, showers, or other
objects such as tabletops.
 ORIGIN
• Historically, man has desired to create living spaces
which were beautiful, durable, and user friendly. with
that in mind, ceramic tile has been made by man for
4000 years.
• Beautiful tiled surfaces have been found in the oldest
pyramids, the ruins of Babylon, and ancient ruins of
Greek cities.
• Decorative tile work was invented in the near east,
where it has enjoyed a longer popularity and
assumed a greater variety of design than anywhere
in the world.
• During the Islamic period, all methods
of tile decoration were brought to perfection in Persia.
 Glazed bricks relief tile wall,
the Ishtar gate at Babylon, around
Painted and glazed tile 575 B.C. ,Iraq.
of around 880 B.C,
Nimrud.

glazed bricks relief tile wall,

from the palace of Persepolis
around 518 B.C. Iran
Relief tile of the early
13th century,
Afghanistan
Manufacture:
 The raw materials used to create tiles are all found in the
ground.
 These raw materials, like clay is quarried and refined.
 They are then mixed.
 A dry mixture of clay, Magnesium silicate and other
ingredients are pressed into a mould, and then fired at an
extremely high temperature.
 The ingredients used in this process are slightly wet.
 They are forced through a nozzle, which forms the tile’s shape.
 Other methods of creating tiles are slush mould and beehive
kilns.
Types of Tiles:
 There are many types of tiles used for residential and
commercial applications.

1. Roof tiles

2. Floor tiles

3. Pebble tiles

4. Ceiling tiles

5. Wall tiles
Roofing Tiles:

• Roof tiles are designed mainly to keep

out rain, and are traditionally made from
locally available materials such as clay
or slate.
• Flat tiles - the simplest type, which are laid
in regular overlapping
Flooring tiles:
• These are commonly made of ceramic or stone.
• Recent technological advances have
resulted in rubber or glass tiles for floors as well.
Pebble tiles:
 Pebble Tiles is a composite material made up
of marble pebbles or pieces of natural stone in
different sizes, bound together with a
transparent white or colored resin.
 Ceiling tiles
 Ceiling tiles are type of tiles used for covering ceilings of
rooms.

 Suspended ceilings
 Acoustic Ceilings
 Decorative Ceiling Tile
Wall Tiles:
 The concept behind using wall tiles is decorating the
interior of a home without adding much stuff to the
home.
USES OF TILE
 Uses:
 Here are some places around the home
that can benefit from tile applications.
 COUNTER
 BATHROOM
 BACKSPLASH
 FLOORING
 WALL ACCENTS
 EXTERIOR
COUNTER
 Ceramic tile is among the most common materials for
kitchen countertops.
 Because it's hard and water-resistant, it holds up
extremely well to the moist and often humid
environment of the kitchen.
BATHROOM:

 Mostly used on floor

 They are also commonly used in walls.
 BACKSPLASH :

 Almost all backsplashes are made of tile because of its natural

water resistance.

 Some people prefer stone or marble, but these are expensive

materials.
 FLOORING :

 Tile is one of the cheapest flooring options,

especially compared to popular materials such as
hardwood and marble.
 Most tiles can withstand heavy use in living rooms and
the heat and moisture of bathrooms.
 WALL ACCENTS:

 Small decorative tiles make great accents for walls,

counters, and flooring.
 They usually come in stronger, deeper colours and feature
interesting patterns, often to complement the colour of
bigger tiles.
EXTERIOR:
Some tiles can actually be used on the exterior walls of
your home.
 These are usually decorative ones made to look like
natural materials, such as wood and stone.
 They make great alternatives to exterior painting, since
they don't fade and can withstand most outdoor
elements.
Earthenware
Is the term for pottery that has not been
fired to the point of vitrification and is
thus porous. Many types of pottery have
been made from it from the earliest
times. Until the 18th century it was the
most common type of pottery outside
the far East.
Earthenware is a type of clay
that when fired to make
pottery is soft and can be
scratched with a knife. It is
opaque and has an earthy or
granular fracture. It is
generally easier to shape on
the wheel than porcelain.
Due to its porosity
earthenware must
be glazed in order to be
watertight.
Earthenware articles may be thick and heavy
or as thin as bone china and porcelain,
though they are not translucent and are more
easily chipped. They are less strong than
stoneware.
Earthenware may be biscuit (or
"bisque") fired to temperatures
between 1000 and 1150 °C (1800
and 2100 °F) and glost-fired(or
"glaze-fired")to between 950 to
1,050 °C (1,740 to 1,920 °F), the
usual practice in factories and
some studio potteries. Some
studio potters follow the reverse
practice, with a low-
temperature bisque firing and a
high-temperature glost
firing.The firing temperature will
be determined by the raw
materials used and the desired
characteristics of the finished
ware.
After firing most earthenware bodies
will be colored white, buff or red. For
red earthenware, the firing
temperature affects the color of the
clay body. Lower temperatures
produce a typical red terracotta
colour; higher temperatures will
make the clay brown or even black.
Every clay has a temperature at
which the body becomes weak and
sags. Higher firing temperatures may
cause earthenware to bloat.
Earthenware comprises "all
primitive pottery whatever the
colour, all terra-cottas, most
building bricks, nearly all
European pottery up to the
seventeenth century, most of the
wares of Egypt, Persia and the
near East; Greek, Roman and
Mediterranean, and some of the
Chinese; and the fine
earthenware which forms the
greater part of our tableware
today
 5.porcelain
Porcelain (also known as china or fine
china) is a ceramic material made by
heating materials, generally
including clay in the form of kaolin, in
a kiln to temperatures between 1,200 and
1,400 °C. Porcelain can informally be
referred to as "china" or "fine china.
Properties associated with porcelain include

• low permeability
• Elasticity
• considerable strength
• Hardness
• Toughness
• Whiteness
• translucency
• resonance
• and a high resistance to chemical attack and thermal
shock.
Bathroom fittings

• Because of its durability, inability to rust and

nonporous nature (porcelain has an absorption
rate of less than .5%), glazed porcelain has been in
use for personal hygiene .
• porcelain chamber pots were commonly found in
higher-class European households
Porcelain toilet bowls, bidets and basins are still
produced, though the tougher stoneware is more
common.
• However bath tubs are not made of porcelain, but
often of so-called porcelain enamel on a metal
base, usually of cast iron.
 BRICKS
• Bricks are one of the oldest known building materials dating back to
7000BC where they were first found in southern Turkey and around
Jericho. The first bricks were sun dried mud bricks. Fired bricks were
found to be more resistant to harsher weather conditions, which made
them a much more reliable brick for use in permanent buildings, where
mud bricks would not have been sufficient.
• Bricks now
• Bricks are more commonly used in the construction of buildings than
any other material except wood. Brick and terracotta architecture is
dominant within its field and a great industry has developed and
invested in the manufacture of many different types of bricks of all
shapes and colours. With modern machinery, earth moving
equipment, powerful electric motors and modern tunnel kilns, making
bricks has become much more productive and efficient. Bricks can be
made from variety of materials the most common being clay but also
calcium silicate and concrete. With clay bricks being the more popular,
they are now manufactured using three processes soft mud, dry press
and extruded. Also during 2007 the new ‘fly ash’ brick was created
using the by-products from coal power plants.
How bricks are made?
 The traditional way

Bricks are made from wetting clay which

you press it into a mould and then bake
the clay in an oven until it is hard.
• Raw Materials

• Natural clay minerals, including kaolin and shale, make up the main body of
brick. Small amounts of manganese, barium, and other additives are blended
with the clay to produce different shades, and barium carbonate is used to
improve brick's chemical resistance to the elements. Many other additives
have been used in brick.

• A wide variety of coating materials and methods are used to produce brick of a
certain color or surface texture. Sometimes a flux or frit (a glass containing
colorants) is added to produce surface textures..Other materials including
graded fired and unfired brick, nepheline syenite, and graded aggregate can be
used as well.
• The Manufacturing
Process
1-Grinding, sizing, and combining
raw materials
2-Extrusion
3-Coating
4-Drying
5-firing
Brick format
• The format of brick is 90mm x 90mm x 90mm and 190mm x190mm
x 190mm .

• With mortar joints ,the size of these bricks are taken as 200mm x
100mm x 100mm and 200 mm x 100 mm x 50 mm .

• The most common brick size is the ‘Imperial Brick’, which measures
222mm long x 106mm wide x 73mm high with a mass of between
3.0kg.

• There are also other sizes and formats available.

Types of bricks
• Concrete Bricks
These bricks have either pale green or gray color. These are
prepared from a small, dry aggregate concrete which is formed
in steel molds by using vibration and compaction. The entire
manufacturing process is incurred either in an egg Layer or
static machine. Rather than firing, the curing process is used to
convert the blocks thus prepared into bricks under low pressure
steam.

• High Alumina Bricks

High alumina bricks from 50% upto 90% Alumina are made with
various selected superior grade aggregates to meet the various
service conditions of various types of furnaces like laddie, blast
furnace, cement and sponge iron Rotary Kiln, calciner , etc., The
90% alumina dense bricks are manufactured from tabular
alumina purer micro fine alumina and other special type raw
material and fired in ultra high temperature kiln at 1650-
1700BC. Due to the intent micro structural features of the raw
materials used for these bricks, they have excellent resistance to
wear and thermal shock.
•Fire Brick
A fire brick is a block of ceramic material used in masonry
construction and sized to be layed with one hand using mortar.
Bricks may be made from type of material .These are built primarily
to withstand high heat and also find applications in extreme
mechanical, chemical, or thermal stresses. The brick is widely used
as refractory insulating bricks for maintaining insistent temperature.
•Light Weight Hollow Blocks
This blocks are used in construction of houses in earthquake prone
areas. These bricks are made of fly ash, cement, lime, gypsum, stone
dust etc. Available in different sizes. Hollow concrete blocks is used
as substitute for conventional bricks or stones used in construction
of buildings. And the blocks' importmant feature
Properties of bricks
• Aesthetic
Bricks offer natural and a variety of colors, including various
textures
• Strength
Bricks offer excellent high compressive strength.
• Porosity
The porosity of bricks in attributed to its fine capillaries. The
ability to release and absorb moisture is one of the most
important and useful properties of bricks, regulating
temperatures and humidity inside structures.
• Fire Resistance
When prepared properly a brick structure can give a fire
protection maximum rating of 6 hours
• Sound Insulation
The brick sound insulation is normally 45 decibels for a 4.5
inches brick thickness and 50 decibels for a nine inch thick brick.
•Insulation
Bricks can exhibit above normal thermal insulation when
compared to other building materials. Bricks can help regulate
and maintain constant interior temperatures of a structure due
to their ability to absorb and slowly release heat. This way bricks
can produce significant energy savings, more than 30% of energy
saving, when compared to wood.
• Wear
A brick is so strong, that its molecular composition provides
excellent wear resistance.
• Efflorescence
Efflorescence forms on concrete structures and surfaces when
soluble salts dissolved in water are deposited and accumulated
on surfaces forming a visible scum.
Classification
The bricks used in construction are
classified as:

• First class bricks

• Second class bricks
• Third class bricks
• Fourth class bricks
Tests on bricks
• Crushing strength test
• Water Absorption test
• Efflorescence test
• Hardness test
• Size, Shape and Color test
• Soundness test
• Structure test
USES
• Structural uses: such as foundations walls and floors.
• Decorative/ornamental uses: May be cast to from moldings and
other decorative features may be carved also may be used in
a variety of colors, textures, bonds and joints.
• May be concealed by other finish materials such as stucco,
plaster or paint, or may be exposed both on
the interior and exterior.
• Bricks are also used in the metallurgy and
glass industries for lining furnaces.
• They have various uses, especially refractory bricks such
as silica, magnesia,
chamotte andneutral (chromomagnesite) refractory
bricks. This type of brick must have good thermal shock
resistance, under load, high melting point, and satisfactory
porosity.
• Bricks are used for building and pavement . Earlier
brick pavement was found incapable of
withstanding heavy traffic,but it is coming back into use as
a method of traffic calming or as adecorative
surface in pedestrian precincts.
Advantages
• The use of materials such as brick and stone can increase the
thermal mass of building, giving increased comfort in the heat
of summer and cold of winter and can be ideal for passive
solar applications.
• Brick typically will not require painting and so can provide a
structure with reduced life cycle costs, although sealing
appropriately will reduce potential spalling due to
frost damage. Concrete block of the non
decorative variety generally is painted or stuccoed if exposed.
• The appearance especially when well crafted, can impart an
impression of solidity and permanence.
• Brick is very heat resistant material and thus will provide good
fire protection.
• Being much more resistant
to cold and moist weather conditions, brick enabled the
construction of permanent buildings in regions where the
harsher climate precluded the use of mud bricks.