High pressure resistant clay-based brick composition and production method of said composition

Abstract

The invention relates to a high pressure resistant clay-based brick composition and a production method of said brick composition The high-strength brick subject to the invention provides maximum usage efficiency with its physical strength. Furthermore, no components harmful to human health or the environment are used in the production of the brick, thereby enabling a natural structure and allowing it to be used for the creation of breathable living spaces.

Description

[0001] DESCRIPTION

[0002] HIGH PRESSURE RESISTANT CLAY-BASED BRICK COMPOSITION AND PRODUCTION METHOD OF SAID COMPOSITION

[0003] Technical Field of the Invention

[0004] The invention relates to a high pressure resistant clay-based brick composition and a production method of said brick composition. The high-strength brick subject to the invention provides maximum usage efficiency with its physical strength. Furthermore, no components harmful to human health or the environment are used in the production of the brick, thereby enabling a natural structure and allowing it to be used for the creation of breathable living spaces.

[0005] State of the Art

[0006] In architecture, each of the elements that come together to form a structure (foundations, walls, columns, beams, slabs, stairs, and roofs) is constructed using various building materials. Wood, natural stone, clay, metal, glass, plastic-based materials and binder (gypsum, cement, lime) materials are defined as the main building materials. Clay is defined as a very fine-grained soil type consisting mostly of feldspar and silicate minerals that shrinks when dry, increases in volume when wet, and releases its water when compressed. Materials made from clay are divided into two categories: fired and unfired. Unfired material, known as adobe, is one of the oldest building materials obtained by mixing soil with straw and water, pouring it into molds, and drying it first in the shade and then in the sun. The first stage in adobe making is the kneading of the clay and its preparation by hand. The second stage is when it is shaped in molds and dried in the sun. The adobe produced in these two stages deteriorates more easily in harsh climatic conditions as it is dried under the sun. People who knew ceramic firing methods must have fired adobe for this reason, which represents a third stage, namely the production of bricks, which is the fired material. Brick as a building and decoration material has been used for centuries due to its ease of production and low cost [1].

[0007] Brick is widely used due to the ease of supply and use of the earthen material, as well as its cheapness. Brick has the advantages of being easily produced wherever suitable clay is available for production, having a lower unit weight than stone and concrete, having higher thermal insulation, being easy to use during construction due to its standard dimensions, and keeping the wall thickness thin. In addition, their compressive strength, water absorption, frost resistance, and resistance to external influences are also quite high when produced in accordance with the technique [2], Brick production stages consist of 5 stages: raw material preparation, shaping, drying, firing, and packaging-shipping. Additives such as silica, sand, chamotte, feldspar, iron oxide, calcium carbonate are prepared and ground to be mixed with clay. The ground materials are mixed with water to form a pulp. At this stage, plasticizers, colorants, and other chemical additives are added. After the mixture is formed into bricks by means of a vacuum extruder machine, long strips of bricks are cut to the desired dimensions. The shaped bricks are dried naturally by keeping them outdoors or indoors for a certain period of time to reduce the moisture content, or the bricks are dried faster by using drying chambers or tunnel kilns in facilities. The dried bricks are fired at high temperatures. Drying is the process of removing the water present in the clay and added to bring it to a consistency suitable for shaping by various methods. Firing is the last stage in brick production. During the drying phase of the clay, its dimensions decrease (shrinkage) due to the loss of its free water and the water it absorbs later. During firing, the clay is subjected to chemical reactions. At around 300°C, organic substances burn completely and lose their molecular water between 450-650°C. This new material formed by firing the clay pulp between 850-950°C is now a product that is hard, does not change its shape, and that has certain strength and color [3]

[0008] The properties of the brick vary according to the mixture ratio of the brick soil, the production technique, the way it is fired, and the temperature at which it is fired. In today's bricks, the height of blend bricks varies between 5.4 - 6.3 cm; width between 9.2-11.8 cm, and length between 20.5-22.7 cm. These bricks have a compressive strength of less than 7.5 MPa as well as low water absorption capacity and freeze-thaw strength. Water absorption values of factory bricks are low and maximum 18%. While the compressive strength of these bricks varies between 6-10 MPa, this value increases up to 24 MPa in dense bricks [4], In the present art, the most widely used main component in brick production is clay, which hardens when dried and fired to increase the durability of the brick, and different types of kaolin, illite and montmorillonite are also used. Sand is generally used as filling material to reduce the plasticity of clay and provide stability. Straw, sawdust, rice husks are used as organic materials to create porosity by burning during brick production, as porosity increases thermal insulation and makes the brick lighter. In addition to these components, plasticizers can be used to improve the workability of the clay, binders to increase the strength of the brick, and water retainers to prevent cracking during drying and firing. Furthermore, in the state of the art in brick production, manganese is used to improve the color properties of bricks and to increase some of their mechanical properties. Manganese improves the color tones of the bricks, provides a more homogeneous color distribution and increases the mechanical strength of the brick. However, said element increases the cost of brick production, and the use of high amounts of manganese causes the brick to break. In addition, the release of manganese into the environment has negative impacts on the environment and health.

[0009] Various elements are used in brick production to improve the physical, chemical, and mechanical properties of bricks. These elements are added to clay and other raw materials to improve the durability, aesthetics, and performance of bricks. In the state of the art, a study conducted by Qimen et al [5] is related to the improvement of brick building material properties using perlite and boron waste, an industrial waste. In the study, brick samples are produced by substituting 5%, 10%, 15% and 20% of boron waste and keeping 5% perlite material constant. The highest pressure value obtained in the study was 30.42 MPa (30.42 N / mm2). Another study by Espeuelas et al [6] in the state of the art relates to the use of an industrial by-product rich in MgO (magnesium oxide) as a binder in the production of unbaked clay bricks. In said study, it is explained that MgO has shown the ability to improve the mechanical properties of clay bricks in the same way that lime does.

[0010] The limitations and insufficiencies of the solutions in the present art, the high manganese content of the dry mix used in the production of bricks, the resulting environmental problems and increased costs, the problems in the use of bricks as building materials due to their low level of resistance to pressure, and the average life expectancy of existing bricks of 50 years have made it necessary to make developments in the related technical field. Summary and Objects of the Invention

[0011] The invention describes a high pressure resistant clay-based brick composition and a production method of said brick composition. The high-strength brick subject to the invention provides maximum usage efficiency with its physical strength. Furthermore, no components harmful to human health or the environment are used in the production of the brick, thereby enabling a natural structure and allowing it to be used for the creation of breathable living spaces.

[0012] The object of the invention is to provide a brick that is resistant to high pressure and has a high hardness and longer life. In the production of the brick subject to the invention, boron, magnesium and to a lesser extent manganese are used as dry raw materials compared to the present art. Thanks to said components, the brick produced has high strength and hardness. Furthermore, since the brick subject to the invention is physically more durable than other bricks in the present art, the service life of the said brick is also longer due to its durability.

[0013] Another object of the invention is to minimize environmental damage in brick production. The invention uses 15 grams of manganese per 3,250 grams of brick. By keeping this ratio low at this level, the negative effects of manganese on the environment and human health are minimized. Furthermore, the brick subject to the invention is free from asbestos and sulphates.

[0014] An object of the invention is to produce bricks at low cost. The brick subject to the invention does not require additional plastering or painting thanks to the use of different colored clays obtained from different clay deposits, and therefore it is produced at low cost.

[0015] Detailed Description of the Invention

[0016] The invention relates to a high pressure resistant clay-based brick and a production method of said brick. The high-strength brick subject to the invention provides maximum usage efficiency with its physical strength. Furthermore, no components harmful to human health or the environment are used in the production of the brick, thereby enabling a natural structure and allowing it to be used for the creation of breathable living spaces. While the bricks in the present art withstand a pressure of 40- 60 N / mm2, the brick subject to the invention withstands a pressure of 270 N / mm2.

[0017] The brick subject to the invention comprises clay, water, manganese, boron, and magnesium. Said brick comprises 3130-3170 grams of clay, 13-17 grams of manganese, 18-22 grams of boron, and 77-83 grams of magnesium. In an embodiment of the invention, the brick subject to the invention comprises 3150 grams of clay, 15 grams of manganese, 20 grams of boron, and 80 grams of magnesium When preparing the brick mortar, the amount of water to be added to the mixture will vary accordingly, since the clay used may have different moisture content in each mixture. Said clay comprises less than 5% limestone. Here, boron ensures the resistance of the brick to high pressures, water ensures the saturation level of the clay and homogenization of the mixture prepared in the process step (i) in the method subject to the invention. Manganese, on the other hand, adds physical strength by increasing the toughness of the brick, and magnesium enables the brick to withstand high temperatures.

[0018] In the invention, a clay-based brick with dimensions of 5x6x20 cm, slightly reddish, in the range of 3238-3292 grams and with an optimum weight of 3250 grams is produced.

[0019] The production method of the brick composition subject to the invention comprises the process steps of: i. preparing clay for clay mix and preparing a mixture by adding manganese, boron, and magnesium respectively, ii. adding water to the prepared mixture and stirring until homogeneous, iii. pouring the homogenized mixture into molds, iv. removing the mortar poured into the mold by giving the mixture in the molds a smooth shape with mold vibration, v. placing the wet bricks on drying bunks and subjecting them to a drying process, vi. firing the dry brick in the kiln, vii. cooling the fired bricks on cooling bunks, viii. washing the bricks after the cooling process is completed. In an embodiment of the invention, a production method of the brick composition subject to the invention comprises the process steps of: i. preparing clay between 3130-3170 grams for clay mixture and preparing a mixture by adding 13-17 grams of manganese, 18-22 grams of boron, and 77- 83 grams of magnesium respectively, ii. adding water to the prepared mixture and stirring until homogeneous, iii. pouring the homogenized mixture into molds, iv. removing the mortar poured into the mold by giving the mixture in the molds a smooth shape with mold vibration, v. placing the wet bricks on drying bunks and subjecting them to a drying process between 24-48 depending on the air temperature, vi. firing the dried bricks in a kiln between 800°C-1100°C vii. cooling the fired bricks on cooling bunks, viii. washing the bricks after the cooling process is completed.

[0020] In another embodiment of the invention, a production method of the brick composition subject to the invention comprises the process steps of: i. preparing clay between 3150 grams for clay mixture and preparing a mixture by adding 15 grams of manganese, 20 grams of boron, and 80 grams of magnesium respectively, ii. adding water to the prepared mixture and stirring until homogeneous, iii. pouring the homogenized mixture into molds, iv. removing the mortar poured into the mold by giving the mixture in the molds a smooth shape with mold vibration, v. placing the wet bricks on drying bunks and subjecting them to a drying process between 24-48 depending on the air temperature, vi. firing the dried bricks in a kiln between 1000°C, vii. cooling the fired bricks on cooling bunks, viii. washing the bricks after the cooling process is completed.

[0021] Industrial Applicability of the Invention

[0022] The invention relates to a high pressure resistant clay-based brick composition and a production method of said brick composition, and is industrially applicable. The invention is not limited to the above descriptions and the person skilled in the art can readily present other different embodiments of the invention. These should be considered within the protection scope of the invention claimed by the claims.

[0023] REFERENCES

[0024] [1] Akyol, A. A., Yildinm, E.E., Erten, E. and Kadioglu, Y.K. (2013). “Olba Kazi Kiremit Ornekleri Arkeometrik Qah§malan”, Seleucia ad Calycadnum, Olba Kazisi Yaymlan, Sayi: 111-2013. s. 251 -269

[0025] [2] Ozi§ik, G. (2000). Yapi Muhendisliginde Tugla Elemanlar ve Yapi Sistemleri. Istanbul: Birsen Yaymevi.

[0026] [3] l§ik, 0. (2010). Konya §erafeddin Camisi Yakimndaki Turbenin Tugla Duvar Malzemesinin Arkeometrik Ybnden Ara§tinlmasi. Qukurova Universitesi Fen Bilimleri Enstitusu Arkeometri Anabilim Dali, Yayinlanmami§ Yuksek Lisans Tezi, Adana.

[0027] [4] §im§ek, O. (2003). Yapi Malzemesi. Istanbul: 2. Baski, BetaYaymevi

[0028] [5] Qimen, S., Qaglar, H., Qaglar, A., & Can, 0. (2020, December 30). Effect of boron wastes on the engineering properties of perlite based brick. Turk Doga ve Fen Dergisi. httDs: / / deraiDark.org.tr / en / Dub / tdfd / issue / 59033 / 731005 [6] Sandra Espuelas, Joshua Omer, Sara Marcelino, Angel Maria Echeverria, Andres

[0029] Seco, Magnesium oxide as alternative binder for unfired clay bricks manufacturing, Applied Clay Science, Volume 146, 2017, Pages 23-26, ISSN 0169-1317, https: / / doi.Org / 10.1016 / j .clay .2017.05.034.

Claims

CLAIMS1. A brick composition, characterized in that it comprises clay, water, manganese, boron, and magnesium.

2. A brick composition according to claim 1 , characterized in that it comprises 3130-3170 grams of clay, 13-17 grams of manganese, 18-22 grams of boron, and 77-83 grams of magnesium.

3. A brick composition according to claim 2, characterized in that it comprises 3150 grams of clay, 15 grams of manganese, 20 grams of boron, and 80 grams of magnesium.

4. A brick composition according to any one of claims 1 -3, characterized in that said clay contains less than 5% limestone.

5. A production method of a brick composition according to any one of claims 1 -4, characterized in that it comprises the process steps of: i. preparing clay for clay mix and preparing a mixture by adding manganese, boron, and magnesium respectively, ii. adding water to the prepared mixture and stirring until homogeneous, iii. pouring the homogenized mixture into molds, iv. removing the mortar poured into the mold by giving the mixture in the molds a smooth shape with mold vibration, v. placing the wet bricks on drying bunks and subjecting them to a drying process, vi. firing the dry brick in the kiln, vii. cooling the fired bricks on cooling bunks, viii. washing the bricks after the cooling process is completed.

6. The method according to claim 5, characterized in that it comprises the process steps of: i. preparing clay between 3130-3170 grams for clay mixture and preparing a mixture by adding 13-17 grams of manganese, 18-22 grams of boron, and 77-83 grams of magnesium respectively,ii. adding water to the prepared mixture and stirring until homogeneous, iii. pouring the homogenized mixture into molds, iv. removing the mortar poured into the mold by giving the mixture in the molds a smooth shape with mold vibration, v. placing the wet bricks on drying bunks and subjecting them to a drying process between 24-48 depending on the air temperature, vi. firing the dried bricks in a kiln between 800°C-1100°C vii. cooling the fired bricks on cooling bunks, viii. washing the bricks after the cooling process is completed.

7. The method according to claim 6, characterized in that it comprises the process steps of: i. preparing clay between 3150 grams for clay mixture and preparing a mixture by adding 15 grams of manganese, 20 grams of boron, and 80 grams of magnesium respectively, ii. adding water to the prepared mixture and stirring until homogeneous, iii. pouring the homogenized mixture into molds, iv. removing the mortar poured into the mold by giving the mixture in the molds a smooth shape with mold vibration, v. placing the wet bricks on drying bunks and subjecting them to a drying process between 24-48 depending on the air temperature, vi. firing the dried bricks in a kiln between 1000°C, vii. cooling the fired bricks on cooling bunks, viii. washing the bricks after the cooling process is completed.

8. The brick composition produced by a method according to any one of claims 5- 7.