Posted: 08 January 2025
As you can see on our fabulous brick selector, Traditional Brick and Stone proudly offers a diverse range of facing bricks in a variety of colours, textures, styles, and sizes to suit every project. We have crafted a comprehensive guide that explains the fascinating brick-making process and showcases the wide range of formats available through Traditional Brick and Stone.
The brick-making process begins with the excavation of clay from natural reserves. Excavated clay is carefully stockpiled to preserve its quality. This raw material serves as the foundation for creating uniform and high-quality bricks.
Clay is a fine-grained soil formed through the weathering and erosion of rocks. Known for its pliability when mixed with water, clay is ideal for shaping and moulding. Once dried and fired, clay hardens to create a durable material, perfect for construction. Its unique properties allow it to maintain the form its form, making it a versatile foundation for brick production.
Once the clay reaches the production facility, it undergoes milling and crushing to break down large clumps into smaller, uniform particles. This step ensures a consistent base material that is easy to work with during the moulding process.
Water and specific additives are then incorporated into the clay to improve its moulding properties and achieve desired aesthetic qualities. For example, additives can influence the color or texture of the final product, allowing manufacturers to create customized finishes.
The forming stage is crucial in defining the shape, texture, and style of the bricks. Depending on the desired characteristics, manufacturers employ different methods, Each technique offers unique advantages and finishes to suit various applications.
In the extrusion process, clay is pushed through a vacuum chamber to remove air. It is then forced through a specially designed mouthpiece and extrusion die, forming a continuous column of clay with a uniform cross-sectional shape. This method ensures precision and allows for the application of finishes, such as textures and colours, before the bricks are cut into individual units using fine wires.
Wirecut bricks in the Traditional Brick & Stone range include options like the Ramecroix, Tamisa, and New Town Red Multi.
TBS Ramecroix - Wirecut Range.
Soft mud bricks are produced using clay with a high water content, making it more pliable. The clay is shaped by pressing it into sanded moulds, which impart a textured finish. This method for many years was done by hand, however modern soft mud manufacturing facilities can now produce soft mud bricks at a high capacity.
Examples of soft mud bricks in our range include the Mystique, St Andrews Multi, and Lava.
TBS Mystique - Soft Mud Collection.
Tumbled bricks are designed to provide a vintage or rustic look, with soft edges and natural irregularities. After forming, these bricks are placed into a rotating drum that gently tumbles them, creating a worn, aged appearance. Notable examples of tumbled bricks are the Barnhouse Blend and Ares from the Traditional Brick & Stone collection.
TBS Reclaimed Mixture - Tumbled Collection
Once the bricks are formed, they enter the drying stage to remove excess moisture. This step is essential to prevent cracking or warping during the firing process. Bricks are typically dried in controlled environments to ensure uniformity and minimize defects.
The firing process is where the bricks gain their strength and durability. Bricks are placed in a kiln and subjected to high temperatures, typically between 900°C and 1,200°C, depending on the type of clay and desired finish. The intense heat hardens the clay, setting its shape and enhancing its structural properties. Variations in firing techniques can also influence the colour and texture of the finished bricks, providing additional customization options.
After firing, bricks can undergo various surface treatments to enhance their appearance. These treatments may include adding glazes, applying textures, or incorporating unique colours. Surface finishes not only improve aesthetics but also add protective properties to the bricks.
Waterstruck bricks are manufactured in the same way as soft mud bricks, however they use water as the release medium, creating a smooth waterstruck feature. Examples in the TBS range of waterstruck bricks include the Old Pluckley Blend and the Gillingham Red
TBS Old Pluckley Blend - The Waterstruck Range
To ensure consistency and durability, finished bricks undergo rigorous quality control checks. This includes examining their dimensions, strength, and appearance before the bricks go on to the packaging stage.
The next stage when produciton is completed is packaging. Traditional Brick & Stone supply all our bricks on free non returnable pallets and they are wrapped and banded in bags with a high percentage of recycled content as we continue to reduce our environmental impact.
Traditional Brick & Stone has depots located around the UK with a high volume of stock ready to be delivered by one of our experienced brick hauliers. We can offer delivery on a variety of different vehicles including Rigid, Artic Crane, Flat and Wagon & Drag.
*The above is a rough guide and may vary depending on the individual product.
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