Lyla Lindsey
Bricks are one of the most durable and highly used building materials in the construction industry. They are renowned for their load-bearing properties, durability, and economical benefits. In Australia, bricks have been used for decades in the construction of many homes. The process of making bricks has remained consistent over thousands of years, but technological improvements have allowed for more automation. In Australia, companies like Austral Bricks and Krause Bricks use a combination of traditional brickmaking methods and modern technology to produce high-quality bricks. The production of bricks involves several stages, from the extraction of raw materials like clay to moulding, drying, firing, and final quality checks.
| Characteristics | Values |
|---|---|
| Primary ingredient | Clay |
| Other ingredients | Various types of clay, shales |
| Extraction of raw materials | Quarries |
| Preparation steps | Unsoiling, Digging, Cleaning, Blending, Tempering |
| Shaping methods | Hand Moulding, Machine Moulding |
| Firing temperature | 1000-1200°C |
| Types of kilns | Down Draught kilns, Hoffman kilns, Tunnel kilns |
| Brick companies | Krause Bricks, Austral Bricks, State Brick Works, PGH |
| Brick manufacturing locations | NSW, Victoria, Tasmania, South Australia, Western Australia, Queensland |
| Recycled bricks | The Brick Pit |
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What You'll Learn
The history of brick-making in Australia
By the 1830s, Sydney's surface deposits of clay were being depleted, but the discovery of shale provided an alternative. When mixed with clay and water, shale could be moulded and fired, resulting in stronger bricks. This innovation, along with the importation of grinding and crushing machines from the US and Great Britain, marked the beginning of technological advancements in Australia's brick-making industry.
The evolution of brick moulding methods is particularly interesting. Initially, bricks were hand-thrown sandstocks, which later transitioned to extruded wire-cut bricks (circa 1840 onwards). This was followed by the introduction of dry-pressed bricks and, eventually, modern extrusion technologies in the early 20th century. However, many brickyards continued to use hand-moulding methods, and it was likely not until after World War I that machine-made bricks became the majority.
The Austral Brick company, founded in 1908, is a notable example of Australia's brick-making history. It quickly established itself as a major player in the industry by the outbreak of World War I in 1914. Over the years, the company has been associated with influential figures such as William King Dawes, and under the leadership of his successors, it expanded into a national organisation with manufacturing operations across Australia.
Today, brick-making in Australia combines traditional methods with modern technology and automation. Companies like Krause Bricks pride themselves on using old-school techniques passed down through generations, while also adopting the latest advancements to enhance efficiency and quality. Additionally, sustainability practices have gained prominence, with companies like The Brick Pit specialising in recycled bricks to reduce environmental impact and preserve the historical value of older bricks.
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Extraction of raw materials
The first step in brick manufacturing is the extraction of raw materials. Clay, the primary ingredient, is sourced from quarries using various methods and transported to manufacturing facilities. Other raw materials used in brick production include shale and sand.
Upon arrival at the plant, the clay undergoes a series of preparation steps. First, the top layer of soil, which may contain impurities, is removed to access pure clay. The cleaned clay is then excavated and spread out to weather, allowing it to break down naturally. Next, stones, roots, and other foreign materials are removed to ensure a consistent texture.
Different types of clay may then be mixed or blended to achieve the desired properties for the final product. Water is added to the clay, and the mixture is left to mature, enhancing its plasticity and making it suitable for moulding. These preparation steps are crucial for producing high-quality bricks with uniform characteristics.
After preparation, the clay is ready to be shaped into bricks. In Australia, two primary methods are used: hand moulding and machine moulding. Hand moulding is a traditional and labour-intensive process that involves manually pressing clay into wooden or metal moulds. Machine moulding, on the other hand, uses machines to extrude clay through a die, cutting it into bricks of uniform size and shape.
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Shaping methods
There are two primary shaping methods used in Australia: hand moulding and machine moulding. Hand moulding is a traditional and labour-intensive method that involves manually pressing clay into wooden or metal moulds. This process often results in unique textures and slight variations, adding character to structures. Machine moulding, on the other hand, is the modern manufacturing method that uses machines to extrude clay through a die, creating bricks of uniform size and shape. This method is highly efficient and consistent for large-scale production.
The extrusion method, a type of machine moulding, is the most commonly used shaping technique. It produces wire-cut bricks and involves forcing clay through a die to create a continuous ribbon, which is then cut into individual bricks. This process ensures uniformity and precision in brick size and shape.
Another shaping method is pressing, where a steel mould is used for the compression process. This results in bricks with smooth and sharp edges, along with a small depression on the top. This method is less commonly used compared to extrusion.
In small-scale production, bricks are often solid without holes. However, in some cases, a "frog" (an indentation on one bed face) may be included. This can assist in moulding and shorten drying time, but it also increases mortar usage during wall construction. Perforated bricks, on the other hand, are exclusively produced by extrusion machines and offer similar advantages to frogged bricks.
After shaping, bricks may undergo further cutting and shaping to meet specific construction requirements. This can be done using a cold chisel and hammer for rough cuts or a power/diamond saw for clean, precise cuts.
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Firing process
Firing is a critical stage in the brick-making process, where bricks gain their strength and durability. In this stage, the bricks are baked in a kiln, which makes them hard and long-lasting. The term 'firing' is used to describe the process of 'baking' and setting the bricks after they have been shaped and dried.
In Australia, there are three basic kiln types used for firing bricks: Down Draught Kilns, Hoffman Kilns, and Tunnel Kilns. Down Draught Kilns are traditional kilns where heat circulates from the top down, ensuring even firing. Hoffman Kilns are continuous kilns with multiple chambers, allowing for efficient mass production. Tunnel Kilns are modern kilns where bricks move through a long, tunnel-like chamber, experiencing gradual temperature changes for uniform firing.
During the firing process, the bricks are baked between 1000 and 1200 degrees Celsius, with the temperature varying depending on the desired colour and clay used. Lighter bricks, such as Ghost or Mid-Blend colours, are fired at lower temperatures, while higher temperatures are used to produce darker colours like Grampian Blues or Nero.
The firing process involves placing the bricks in the kiln and gradually increasing the temperature to the desired level. The bricks are then baked at the specified temperature for a set period, allowing the clay to transform into a durable material. After firing, the bricks are allowed to cool gradually to prevent thermal shock. This gradual cooling process is crucial to ensure the stability and integrity of the bricks.
Once cooled, the bricks undergo quality checks for strength, size, and appearance. They are inspected for any defects or inconsistencies that may have occurred during the firing process. Bricks that pass the quality checks are then packaged and distributed for construction projects, ready to be used in building walls, pavements, and other masonry applications.
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Recycled bricks
Recycling bricks is a sustainable practice that has gained popularity in Australia. It involves salvaging bricks from demolished structures, cleaning and sorting them, and repurposing them for new construction projects. This process helps preserve the historical and aesthetic value of older bricks while also reducing the environmental impact of new brick production.
One notable company specialising in recycled bricks is The Brick Pit, which has promoted sustainability in the Australian brick industry. They have supplied recycled bricks for several notable projects, including the University of Wollongong's Sustainable Buildings Research Centre, the first building in Australia to achieve Living Certification.
Another company, Richies Recycled Bricks in Canberra, offers a similar service, salvaging, cleaning, and stacking existing house bricks for reuse. They cater to those seeking to dismantle and reuse existing brickwork or find matching bricks for their projects.
Recycled Brick Centre in Sydney is the city's largest retailer of recycled bricks, offering antique, second-hand, used, salvaged, and convict bricks. They provide paving-grade and feature wall bricks, ensuring the preservation of old-quality bricks and resources.
Cheap As Bricks is another notable company, selling quality recycled and used bricks across the Sydney Metropolitan area, the Northern Beaches, and the Blue Mountains. They source their bricks from demolition sites and supply them to architectural firms, building companies, and landscapers.
While recycled bricks are in demand across Australia, they are less common in Queensland due to the prevalence of timber housing. However, several salvage yards in the state offer recycled bricks, such as Underwood Demolition Market and Anton Demolitions.
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Frequently asked questions
Yes, bricks are made in Australia.
The process of manufacturing bricks in Australia involves several key stages. First, raw materials like clay are extracted from quarries and transported to manufacturing facilities. The clay is then cleaned, excavated, and spread out to weather. After this, the clay is blended, tempered with water, and moulded into bricks. The bricks are then dried and fired in kilns at temperatures exceeding 1,000°C. Finally, the bricks are cooled, inspected, and packaged for distribution.
There are three basic types of kilns used in Australia for brick firing: Down Draught kilns, Hoffman kilns, and Tunnel kilns. Down Draught kilns are traditional kilns where heat circulates from the top down. Hoffman kilns are continuous kilns with multiple chambers for efficient mass production. Tunnel kilns are modern kilns with a long, tunnel-like chamber, allowing for gradual temperature changes during firing.
Yes, there are several notable brick manufacturers in Australia. Austral Bricks, founded in 1908, is recognised as a leading manufacturer of quality building products. Krause Bricks combines traditional brickmaking methods with modern technology to produce premium-quality bricks. The Brick Pit specialises in recycled bricks, salvaging and repurposing bricks from demolished structures, contributing to sustainability and waste reduction.
Traditional methods of brick-making in Australia include hand moulding, where clay is manually pressed into wooden or metal moulds, leaving unique textures and slight variations. Early brick makers often used their thumbs or fingers to make marks on the bricks to keep count of their work. Sometimes, a small recess called a "frog" was created in the mould to help with bonding and provide space for mortar. Markings like stamps, letters, or symbols were also added to identify the maker or the convict who made the brick.
