Assignment No: 03

Visit to A Brick Kiln

Introduction:

We had an opportunity last weekend to visit a brick kiln names “Peshawar Bricks” situated
in a village Bhalot, Thata Khalil, Taxila. It was near M-1 motorway and a cement factory. Our
group expected the kiln near the near housing colonies, but it was situated at the place with no
houses there, however, the kiln sat in the midst of the green fields, and some other kilns were
also near it. We didn’t know much about them. Luckily, we went to a kiln that uses modern
techniques for mixing soil to make clay for making bricks. The owner was requested to help us
visit different places, and to show us, how they make bricks? He sent his brother as a guide for
us to show us the methods and techniques they use for making bricks. The guide treated us in a
very good way and his guidance was really appreciable. We met different people belonging to
different areas of Pakistan. Most of them belonged to Pakhtun belt as the kiln was owned by a
Pathan. The labors were working there on low wages even in the harsh weather conditions.
Women were also working there as they were a cheap labor. We are thankful to them to help us
complete a portion of our assignment.

Process for Manufacturing:

The bricks are passed through many processes before baking.
1. Getting Soil and water
2. Mixing to make clay
3. Molding
4. Sun Drying
5. Transportation to brick kiln
6. Baking in Kiln

 Getting Soil :

First of all, the soil is extracted from nearby fertile land by using excavators and
is collected using tractor and dumped to mixing machine by using trolleys.The
clay obtained from different areas vary in composition which is identified by
difference in colour,clays are thoroughly mixed before its addition to blending
machine. The owner doesn’t allow to start the machine until 400 to 800 trips of
the trolley’s soil is unloaded near the machine.
 Water Source

The water is obtained by a nearby tank that is refilled by a bore or well. The
tanker on the kiln is about 50 gallons and contains clean water for bricks
manufacturing. Contaminated water is disposed to sanitary lines on daily basis.
Blending machine which is about 500 meter away from water tank is attached to it
through PVC pipes.The placemat of water tank at certain height makes it easy to
transport water to blending machine.

 Mixing: (Machine Mixing)

One tractor is used to start the machine which has shaft attached to it and the
trolley is used to collect the freshly made clay from the machine. Mixing done by
machine is uniform and led to achieve brick with better corner. This clay is then
transported by using trolleys parked under the machine to the labors for molding
purpose. It requires less labor for mixing and reduces time for making mud paste
which in result led to increase per day production of kiln. Mixing using machines
is a bit expensive for the owner as it utilizes a big amount of fuel for it, but it
produces the best quality of bricks that has an effective strength.
 Molding:

They are then molded by labors using a brick molder and are kept under sunlight
for sun drying. After molding, the bricks are now under the responsibility of the
owner. If the harsh weather such as rain destroys the bricks, it will be his loss, but
the labors will get the cost for molding them.

Molding of Bricks

Dry bricks storage

During the rainy season when it is not possible to mould the paste thus they stored
dried bricks to bake them ,which does not affect their daily production.
 Sun Drying:

After molding, the bricks are kept under sunlight for sun drying. Harsh weather
conditions such as rain can destroy the bricks. It takes 7 to 8 days for bricks to dry
in winter, and 3 to 4 days to dry in summer.

Sun Drying
 Transportation to brick kiln:

After sun drying, the bricks are then transported to brick kiln using horses,
donkeys, and ponies as they are comparatively a cheap source.
Bull’s Trench method

Bull’s trench operation is used in kiln. Bricks are stacked in layers according to
respective class as class A bricks require more heat so they are placed at the base
and then further bricks are placed manual labor is used to stock them. its a
continuous process in which un burnt bricks are stacked while burnt bricks are
removed simultaneously.
 Baking:

The bricks are then placed in the kiln accordingly; the baked bricks are put in
front then partially baked, and at last freshly prepared bricks are placed. The coal
is put in them to burn them. A flow of cool air is made to pass through baked
bricks. The air becomes hotter while passing from baked bricks as they are hot
making the partially baked bricks hot.

It makes the freshly prepared bricks completely dry due to its heat. The air is then
disposed through chimney. The coal is added with respect to time. A measureable
quantity of coal is added in the kiln after every 15 minutes, and about 1 ton of
coal is utilized each day at the kiln for baking the bricks.
 Kliner(Over burnt)

In kiln due to excess heat some of the bricks are overburnt and become unsound
as they changed their shapes and they are used for footings in buildings and
readily available in kiln as by product.

Baking in the Kiln

Types of Bricks:
On inspection, the guide told us that there were four different types of bricks available there i.e
 Type 1
 Type 2
 Type 3
 Clinker
The samples were collected for different tests in Laboratory.

Frog details:
Frog is a depression made on the face of bricks during moulding.  Functions served by frog
in bricks are: 
The mortar accumulated in the frog forms a very good key for subsequent course of brick
above it. 

The frog of that bricks was also indented for makers/owners name. “Z” and “PR1” was
written on them as “Z” stands for “Zahir Khan-the owner” and “PR1” stands for
“Peshawar bricks- the name of the kiln”.
 Size:
Standard size of clay brick is as follow:
Length=8.75 inches

Width= 4.25 inches

Height=2.75 inches

 Strength:

 Production Capacity of the kiln:

The kiln has a production capacity of about 28,000 to 30,000 bricks per day. On
average, seven lands of the kiln are baked each day, and one land contains about
4,200 baked bricks.

 Price of Bricks:

The bricks were rated according to their class and size.

1. First class bricks cost Rs. 8000 for 1000 bricks.

2. Second class bricks cost Rs. 4000 for 1000 bricks.
3. Third class bricks cost Rs. 6000 for 1000 bricks.
4. Clinker costs Rs. 6500 for 1000 bricks.
Decorative and Footpath Bricks
Decorative ricks are also required for architectural and aesthetic purposes used on the buildings
and walls. Whereas footpath bricks are used to make footpaths.

The End