What is brick manufacturing?

Brick manufacturing is the industrial process in which clay is extracted, shaped, dried, and fired into building bricks. This production method has remained fundamentally the same for centuries, though it is now largely mechanised and automated in modern brickworks.

Clay extraction

The manufacturing process begins with the extraction of clay from quarries or river deposits. The composition of the clay largely determines the colour and properties of the finished brick. After extraction, the clay is stockpiled and processed: impurities are removed, and the clay is ground and blended into a homogeneous mass.

Shaping

After preparation, the clay is formed into bricks. In the extrusion method, clay is pressed through a die and cut to size with wires, producing uniform, regular bricks. In the soft-mud process, clay is thrown into moulds, resulting in a more irregular surface texture. The water-struck method is a variant that uses wet moulds to achieve a smoother finish.

Drying

The shaped bricks must be dried before entering the kiln. This takes place in drying chambers at controlled temperature and humidity over a period of 24 to 48 hours. Proper drying is essential to prevent cracking during the firing process. The moisture content is reduced from approximately 20 percent to 2 to 3 percent.

Firing

Firing takes place in tunnel kilns or ring kilns at temperatures between 900 and 1200 degrees Celsius. The firing temperature and duration determine the hardness, porosity, and colour of the brick. Higher temperatures produce harder, darker bricks. The firing process takes an average of two to three days.

Sorting and packaging

After firing and cooling, the bricks are sorted by colour, quality, and size. Bricks that do not meet the required standards are rejected or sold as seconds. Approved bricks are stacked on pallets and shrink-wrapped for transport to construction sites and distributors.

Related terms

• Clay extraction
• Extruded brick
• Hand-moulded brick
• Tunnel kiln
• Sintering
• Brickworks
• Drying chamber

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