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Introduction of Clay and its products in architecture
- 1. Overview Clay and its classification Tiles Bricks Earthenware and stoneware Teracotta Porcelain and glazing
- 2. Clay Clay is naturally occurring mineral that is found almost every where on the surface of the earth making the soil cover or the soft ground.
- 5. China clay
- 6. Fire clay
- 8. Brick clay
- 9. Tiles They are thin slabs of bricks which are burnt in kiln.
- 10. Popular brands of tiles in India
- 11. Types of tiles Common tiles Encaustic tiles
- 12. Common tiles These tiles have different shapes and sizes. They are mainly used for paving, flooring and roofing.
- 13. TYPES OF COMMON TILES FLOOR OR PAVING TILES ROOF TILES DRAIN TILES
- 14. Manufacture of common tiles Preparation of clay Moulding Drying Burning
- 15. Encaustic tiles These tiles are used for decorative purposes in floors, walls, ceiling and roofs The encaustic tiles are manufactured from carefully prepared ordinary clays, colouring materials and sometimes with finer clays. Depending upon the colouring pigment added in the clay, these tiles obtain the desired print or colour after manufacture.
- 16. An encaustic tile usually consists of the following three layers: Body: it is made up of coarser clay. Face: it comprises of a 6mm coat of finer clay and the colouring matter for making the ground of the pattern. Back: it is a thin coat of clay to prevent the tile from warping.
- 17. Market survey Always available in tile and sanitary ware shops. Shop area in Lucknow: raja ji puram, chinhat, patrakarpuram etc. Price vary from 10rupees/sq. feet to 2000rupees/sq. feet. 10-12 pieces in one container.
- 19. The bricks are rectangular block of uniform size made by drying and burning the clay. The common brick is one of the oldest building material The bricks seem to have been produced since the dawn of the civilization in the dried form. At present India has a capacity to manufacture over 100000 million bricks. In India the process of bricks making has not changed since many centuries.
- 20. Brickwork is superior than the stonework due to following reasons : i. Cheaper ii. Lifting devices not required iii. Fire resistant iv. More durable v. Easy to construct openings in brickwork
- 21. Alumina 20% to 30% imparts plasticity in excess causes warping Silica 50% to 60%. Prevents cracking, shrinking and warping in exces causes brittleness Lime not exceeding 5 percent prevents shrinkage in excess causes brick to melt Oxide of Iron about 6% imparts red colour in excess gives blue colour to bricks Magnesia decreases shrinkage in excess leads to decay
- 22. First class bricks table moulded and standard shape. Burnt in kilns. Edges are sharp, square, smooth. Second class bricks ground moulded and burnt in kilns.rough surface and irregular shape. Third class bricks ground moulded and burnt in clamps. Rough surfaces and distorted edges. Used for temporary structures. Fourth class bricks Overburnt bricks with irregular shape. Used as aggregate in construction.
- 23. Preparation of clay unsoiling, weathering, digging, blending, cleaning, tempering. For manufacturing good quality bricks preparation is done in a pug mill. Moulding 1. Hand moulding The bricks are moulded by hand i.e. manually 2. Machine moulding - The bricks are moulded by machine. Drying the moulded bricks are dried before next operation in order to prevent cracking. Artificial drying, circulation of air, drying yard, period for drying, screens Burning It imparts hardness and strength to the bricks.
- 24. A kiln is alrge oven which is use to burn bricks. Two types Intermittent up-draught kilns : Intermittent down-draught kilns
- 25. Well burnt, colour should be uniform, standard size, Should give metallic sound when struck Should not absorb water more than 20 percent. Bricks should be sufficiently hard. Bricks should not drop into pieces Bricks should have low thermal conductivity
- 26. Components of brick earth Preparation of clay and blending Nature of moulding adopted Care taken in drying Burning and cooling process Care taken in unloading
- 27. Location - Rajajepuram, Chinhat, Patrakarpuram Cost - Dark red bricks - Rs 9 Highest Strength Mid dark bricks Rs 8 Average strength Yellow bricks Rs 7 least strength Important points A trolly can contain atleast 40000 bricks Trucks comes out be cheaper You cant directly buy bricks from kiln Usage All building construction works
- 28. EARTHENWARE Earthenware is a glazed or unglazed nonvitrous pottery. It is normally fired below 1200c. Basic earthenware are called terracotta, absorbs liquids such as water. It is made impervious to liquids by coating it with a ceramic glaze.
- 29. CHARACTERISTICS Earthenware exhibits high plasticity hence easy to shape by RAM press, roller-head and potter wheel. Absorbs 5-8% water Low mechanical strength Darker terracotta earthenware due to high content of iron oxide, are widely used for flower pots ,tiles and some decorative.
- 30. PRODUCTION Formulation for contemporary earthenware Kaolin-25% Ball clay-25% Quarts-35% Feldspar-15% Fired between 1000c-1150c and glost fire 950c-1050c
- 31. TYPES OF EARTHENWARE Terracotta Redware Victorian majolica Lusterware Raku yellowware
- 32. STONEWARE It is a broad term for pottery or other ceramics fired at a relatively high temperature Whether vitrified or not, it is non porous, it may or may not be glazed. Often used for high-quality wares as well as utilitarian wares It fired in a kiln at a range of 1100c -1300c
- 33. TYPES OF STONEWARE TRADITIONAL STONEWARE A dense and inexpensive It is opaque and breaks easily Made up of fine-grained secondary plastic clays FINE STONEWARE Made from selected ,prepared and blended raw materials. It is used to make tableware and art ware.
- 34. TYPES OF STONEWARE CHEMICAL STONEWARE Used in chemical industry. THERMAL SHOCK RESISTANT STONEWARE Mixtures of certain materials to enhance thermal shock resistance. ELECTRICAL STONEWARE Historically for electrical insulators. Now, replaced by electrical porcelain.
- 35. RAW MATERIALS IN STONEWARE Naturally occurring stoneware clay or non refractory fire clay. STONEWARE CLAY The minerals are kaolinite, mica and quarts(in small particle size) The clay is soft but contains impurities such as iron and carbon. Dirty in look and plasticity can vary widely.
- 36. RAW MATERIALS NON REFRACTORY CLAY Withstand very high temperatures before melting or crumbling High concentration of kaolinite but lesser amount of mica and quarts. Formulation for stoneware Plastic fire clays 0-100% Ball clays 0-15% Quarts 0-30% Feldspar and chamotte 0-15%
- 37. The terra means earth and cotta means baked. Hence the terra-cotta means the baked earth . Its is thus a type of earthenware or porous pottery made from local clays and glazed with glazes containing galena. It is soft enough to be scratched by a knife. TERRA-COTTA
- 38. MANUFACTURE OF TERRA-COTTA : Preparation of clay. Moulding . Drying of clay. Burning .
- 39. 1) Preparation of clay : Clay should contain 5-8% higher iron oxide and about 1% less lime . The addition of sand, ground glass ,old terra-cotta or pottery gives strength and rigidity to the terra-cotta products . Clay should be free of any impurities such as pebbles, organic matter etc. Crushing and pulverized. Water Is added in required quantity and the ingredients are mixed with spades . Place in damp condition for weathering and tempering . It is then pressed or kneaded in a pug mill ,and is made easy for moulding.
- 40. 2) Moulding : The clay is placed in moulds for required pattern or shapes . Special moulds of plaster of Paris or templates of zinc are used . The size of moulds is determined by keeping due allowance for shrinkage . Sprinkle of fine sand inside the surface of moulds . clay is then pressed in moulds with hands.
- 41. 3) Drying of clay: Moulds filled with clays are left for some days for drying . After drying of the moulds the articles of the terra-cotta are taken out from the moulds . They are again allowed to dry further in a room or under a shed. The drying should be done carefully in a proper controlled temperature. It helps in retaining the correct shape and size of the article.
- 42. 4) Burning: Burnt in special muffle furnaces. Muffle indicates a compartment of a furnace in which things can be heated without contact with the fuel and its product. Damper indicates a metal pate which is provided in an opening to regulate the draught . Dried articles are arranged in muffleand temp. of kiln is raised to about 1200 c . Temp. is maintained for about 4 days and the burnt products are the allowed to cool down in kiln for a period of about 5 days.
- 43. VARIETIES OF TERRA-COTTA The terra-cotta products are of two types: 1) Porous Terra-cotta . 2) Polished Terra-cotta .
- 44. 1) Porous Terra-cotta : To prepare porous terra-cotta ,the saw dust or ground cork is added in clay before moulding. When articles from such clay are burnt in a kiln, the organic particles are burnt and they leave pores in the product. Porous terra-cotta is a fire-proof and a sound proof material. It can be chiselled ,sawn and nailed easily. Light in weight but weak structurally .
- 45. 2) Polished terra-cotta: Also known by fine terra-cotta . Articles are burnt at lower temp. of about 650 C .First burning is known by biscuiting. Coating with a glazing compound and burnt again in kiln at 1200 C temp. .
- 46. MARKET SURVEY Price: 400 rupees 5000 rupees (depends on the quality, build,size etc ). Usuage: Home Decoration, Roofing, ornamental purpose ,industrial areas etc. Important points: light weight ,available in various forms,color and sizes. Location: raja ji puram , chinhat etc.
- 47. Porcelain fine, thin and semi transparent earthenware Also known as Whitewares Porcelains are used for various purpose such as sanitaryware, electric insulators, storage vessels, reactor chambers etc.
- 48. It is hard , brittle and non-porous clay of sufficient purity possessing high degree of tenacity and plasticity are used in preparing porcelains It is prepared of clay , felspar and minerals The constituents are ground and thoroughly mixed in liquid state. The mixture is given the desired shape and is burnt at high temperature.
- 49. Types of porcelain 1. Low Voltage Porcelain 2. High Voltage Porcelain prepared by dry process used for making switch block, insulating tubes, lamp sockets etc. Adding some quantity of aluminia or silicate of magnesia makes it resistant to high temperature upto a certain extent. prepared by wet process Used for making- electrodes, electric furnace reflectors, spark plugs etc.
- 50. 1.. Carbon and Graphite (electrodes, atomic reactor rockets) 2.. Carbon Brick (lining material for electric furnace) 3.Cordierite porcelain (electric furnace refractory bricks) 4.Steatic porcelain (vaccum tubes) 5.Zircon Porcelain (sparkplugs) Types of High voltage porcelain:
- 51. 1. Carbon and Graphite- refractory material of high quality. oxidized at high temperature. used for making electrodes and in the construction of atomic reactor rockets. 2. Carbon Brick- prepared from powder coke and tar. can resist high temperature. used for lining material for electric furnace
- 52. 3. Cordierite porcelain- it contains 22% alumina 35% clay 43% silicate of magnesia. - It is available in porous, partly porous and glassy form. - Used for electric furnace refractory bricks.
- 53. 4. Steatic porcelain- it contains 70 to 90% silicate of magnesis. Used as electrical insulators for high intensity electric current, vaccum tubes, etc. 5. Zircon Porcelain- it contains 45 to 60% zircon 15 to 30 % clay 15 to 30% silicate of zircon. - Its dielectric constant at high temperature is good - used in manufacturing of sparkplugs
- 54. Glazing A glaze is a glassy coat of thickness about 0.1to 0.2mm applied on the surface of an item and then fused into place by burning at high temperature. Purpose: 1.To improve the appearance 2.To make the article durable and impervious 3.To produce the decorative effects 4.To protect the articles from action of atmospheric agencies, chemicals, sewage, To provide smooth surface.
- 55. Methods- oxides and salts of various metals or special refractory colouring agents are added. copper oxide green colour iron oxide red and brown colours. Types- Transparent glaze like glass Opaque glaze like enamels.
- 56. Transparent Glazing: 1. Salt Glazing wet sodium chloride or salt is added in the kiln at high temperature of about 1300C. The salt is vaporized at high temperature and a glass like glaze is formed on the surface of articles dure to sticking of powder of salt. Used for sanitary pipes and chemical stoneware. The colour of articles glazed by this method
- 57. 2. Lead Glazing article is once burnt and it is then dipped in a bath containing oxide of lead and tin. The article is taken out from the bath and it is reburnt at a high temperature. the glaze does not penetrate into the body of ware and can be easily detached from the ware surface. used for terra cotta, fire-clay wares and earthenware.
- 58. give better appearance than that given by burnt material. The superior clay is finely powdered and dried, mixed in sufficient quantity of water to make slip (a plastic cream like substance) The articles are dipped in the slip and then burnt then subsequently heated. The sanitary articles are glazed by this process. Opaque glazing-
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