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Clay is the general term applied to the materials used to manufacture structural clay products The three principal forms in which it occurs have different physical characteristics but similar chemical compositions: Surface clays that are sedimentary and found near the surface of the earth Shales that have been subjected to high pressures that hardened them
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Solid units have cores, cells, or frogs that constitute no more than 25 percent of their gross cross-sectional area Hollow units have a net cross-sectional area that is less than 75 percent of their gross cross-sectional area
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Fire clays that occur at greater depths than either surface clays or shales and are usually mined Clay masonry units are produced by mixing the finely ground clay with water, molding or forming it into the desired shape, drying it, and burning it After the units are formed, they are dried in kilns at temperatures from 110 degrees F to 300 degrees F for 24 to 48 hours After drying, they are burned in kilns that gradually raise the temperature up to a maximum of 1600 degrees F to 2400 degrees F The burning process can take two to five days The materials used to fabricate the clay unit, the fineness with which the materials are ground, the length of burning, and the temperature and rate of burning all affect the clay unit s properties of color, size variation, absorption, compressive strength, and modulus of rupture
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There are four ASTM standards that govern clay masonry bricks, as listed in Table 11 Building bricks are used in both structural and nonstructural applications where appearance is not important These units are used for the interior, hidden wythe of multi-wythe brick walls or the exterior, exposed wythe of walls that are rarely seen or serve utilitarian purposes Face bricks are used for structural or facing components of the wall or both Both building bricks and face bricks are solid units, meaning that they have cores, cells, or frogs that conTABLE 11 C 62 C 216 C 652 C 1088 ASTM Standards for Clay Masonry Bricks Name ( Standard Specification for ) Building Brick (Solid Masonry Units Made From Clay or Shale) Facing Brick (Solid Masonry Units Made From Clay or Shale) Hollow Brick (Hollow Masonry Units Made From Clay or Shale) Thin Veneer Brick Units Made From Clay or Shale
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100% solid
frogged
cored < 25%
cored >25% Hollow Brick ASTM C 652
Solid Brick ASTM C 62 and ASTM C 216 FIGURE 11 Solid and Hollow Clay Brick Units
(Beall and Jaffe, Concrete and Masonry Databook, McGraw-Hill, 2003)
stitute no more than 25 percent of their gross cross-sectional area Hollow bricks may be building bricks or face bricks that have a net cross-sectional area that is less than 75 percent of their gross crosssectional area Hollow and solid clay bricks are illustrated in Figure 11 Thin veneer bricks, which are no more than 13 4 inches thick, are used to provide a non-structural surface finish to a wall All four of the clay brick standards provide for two or more grades of brick units Brick grades, or weathering grades, differentiate the units according to their ability to resist damage caused by cyclic freezing Definitions of the various brick grades are provided in Table 12 Weathering regions within the continental United States are shown in Figure 12 Table 13 lists recommendations for weathering
TABLE 12 Grade SW Brick Grade Definitions Definition severe weathering: high and uniform resistance to damage caused by cyclic freezing and brick may be frozen when saturated with water moderate weathering: moderate resistance to damage caused by cyclic freezing or brick may be damp but not saturated with water when freezing occurs negligible weathering: little resistance to damage caused by cyclic freezing in applications protected from water absorption and freezing exposed to weather not exposed to weather
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