Clinker bricks are partially-vitrified bricks used in the construction of buildings.
Clinker bricks are produced when wet clay bricks are exposed to excessive heat during the firing process, sintering the surface of the brick and forming a shiny, dark-colored coating. [1] [2] [3] Clinker bricks have a blackened appearance, and they are often misshapen or split. [2] Clinkers are so named for the metallic sound they make when struck together. [4]
Clinker bricks are denser, heavier, and more irregular than standard bricks. [3] Clinkers are water-resistant and durable, but have higher thermal conductivity than more porous red bricks, lending less insulation to climate-controlled structures. [3]
The brick-firing kilns of the early 20th century—called brick clamps or "beehive" kilns—did not heat evenly, and the bricks that were too close to the fire emerged harder, darker, and with more vibrant colors, according to the minerals present in the clay. [5] Initially, these clinkers were discarded as defective, but around 1900, the bricks were salvaged by architects who found them to be usable, distinctive, and charming. Clinker bricks were widely admired by adherents of the Arts and Crafts movement. [5] [1]
In the United States, clinker bricks were popularized by the Pasadena, California architecture firm Greene and Greene, who used them for walls, foundations, and chimneys. [6] On the East Coast, clinkers were used extensively in the Colonial Revival style of architecture. [1]
Modern brick-making techniques do not produce clinker bricks, and they have become rare. [1] Builders can procure clinkers from salvage companies; alternatively, some brickmakers purposefully manufacture clinker bricks or produce imitations. [1]
Clinker is sometimes spelled "klinker" which is the contemporary Dutch word for the brick. Both terms are onomatopoeic, derived from the Middle Dutch klinkaerd, later klinker, from klinken (“to ring, resound”). [7]
Clinker bricks are also known as Dutch paving bricks.[ citation needed ] In 18th century New York, the Dutch interspersed dark clinkers with regular bricks. Some used clinkers to spell out their family initials on brick dwellings such as the Jan Van Hoesen House.
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Clinkers consist of bits and ends, field-late and white-burning or red-burning clays. Through different mixtures of the raw ingredients, many varied color nuances can be achieved. For the production of masonry units the source materials—clay and water—are mixed and formed industrially in a string extrusion process. For special purposes, for example the restoration of listed buildings, hand-formed clinkers are used. During the drying process, the water concentration decreases to approximately 3%. Then clinkers are fired at temperatures between 1,100 and 1,300 °C (2,010 and 2,370 °F) in a tunnel kiln (earlier in ring kilns), in contrast to the 800 to 1,200 °C (1,470 to 2,190 °F) temperature range seen with normal bricks.
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In Germany, clinker bricks (German: Klinkerziegel) are named according to the German Institute for Standardization's DIN 105. They differ between full clinker (KMz) with a density of 2.0 to 2.2 kg/dm3 (120 to 140 lb/cu ft) and high hole clinker (KHLz) with a density of 1.6 to 1.8 kg/dm3 (100 to 112 lb/cu ft). Because of their low porosity, clinker bricks are inferior thermal insulators, compared to normal bricks. Canal clinkers are named according to the German Institute for Standardization’s DIN 4051. Clinkers are frost resisting and, thus are suited particularly for facades. The formats of the clinker stones are named according to the German Institute for Standardization’s DIN 1053. Base for the different formats is the normal format (NF) with length 240 millimetres (9.4 in), width 115 millimetres (4.5 in) and height 71 millimetres (2.8 in). For facade layouts architects also order clinkers produced in special dimensions.
For use in facades, it is possible to cope varied shaped elements (e.g., clinker expressionism, see picture). Earlier clinkers were often used in civil engineering works, for example in bridge building, the construction of sewers and hydraulic structures, for mortar floodgates and hoppers or as paving stones for road construction.
The German sculptor Ernst Barlach worked with clinkers, which were produced according to his specifications, for example by the brickyard of Ilse Bergbau AG.[ citation needed ]
Clinker bricks take on a special coloring, often greenish tones, if burnt with peat. The Chilehaus and the Ramada Hotel in Hamburg are famous buildings built with peat-fired clinker. The last ring stove for peat-fired clinker still operating is in Nenndorf near Aurich (East Frisia), producing bricks marketed under the name “Wittmunder Torfbrandklinker” (peat-fired clinker of Wittmund).[ citation needed ]
Greppiner Klinker (clinker of Greppin) is a hard-burnt yellow clinker brick. Greppin clinkers were mainly used for facing railway structures at the end of the 19th and in the early 20th centuries.[ citation needed ]
These reclaimed brick tiles are not sliced from full clinker bricks but from half clinkers. Full clinkers are very hard and if used as flooring would not only rip one’s feet apart but also one’s shoes. The surface of a Klinker brick is so hard that it is almost glass like and any rough edges wouldn’t soften. [8]
Half Klinker bricks have been fired at high temperatures in wood fired kilns over 100 years ago but because they have been sun dried prior to being loaded in the kiln, there has not been the same intensity of vitrification as with a full clinker brick. This makes them softer underfoot and therefore far more desirable for use in flooring. They also wear and soften with age.
Because the kilns have been wood fired there is a certain amount of inconsistency with the temperatures in different parts of the kiln and this is what gives the Brick tile its distinctive color variation.
A brick is a type of block used to build walls, pavements and other elements in masonry construction. Properly, the term brick denotes a block composed of dried clay, but is now also used informally to denote other chemically cured construction blocks. Bricks can be joined using mortar, adhesives or by interlocking them. Bricks are usually produced at brickworks in numerous classes, types, materials, and sizes which vary with region and time period, and are produced in bulk quantities.
A cement is a binder, a chemical substance used for construction that sets, hardens, and adheres to other materials to bind them together. Cement is seldom used on its own, but rather to bind sand and gravel (aggregate) together. Cement mixed with fine aggregate produces mortar for masonry, or with sand and gravel, produces concrete. Concrete is the most widely used material in existence and is behind only water as the planet's most-consumed resource.
Pottery is the process and the products of forming vessels and other objects with clay and other ceramic materials, which are fired at high temperatures to give them a hard and durable form. Major types include earthenware, stoneware and porcelain. The place where such wares are made by a potter is also called a pottery. The definition of pottery, used by the ASTM International, is "all fired ceramic wares that contain clay when formed, except technical, structural, and refractory products". In art history and archaeology, especially of ancient and prehistoric periods, "pottery" often means vessels only, and sculpted figurines of the same material are called "terracottas".
Portland cement is the most common type of cement in general use around the world as a basic ingredient of concrete, mortar, stucco, and non-specialty grout. It was developed from other types of hydraulic lime in England in the early 19th century by Joseph Aspdin, and is usually made from limestone. It is a fine powder, produced by heating limestone and clay minerals in a kiln to form clinker, grinding the clinker, and adding 2 to 3 percent of gypsum. Several types of portland cement are available. The most common, called ordinary portland cement (OPC), is grey, but white Portland cement is also available. Its name is derived from its resemblance to Portland stone which was quarried on the Isle of Portland in Dorset, England. It was named by Joseph Aspdin who obtained a patent for it in 1824. His son William Aspdin is regarded as the inventor of "modern" portland cement due to his developments in the 1840s.
Porcelain is a ceramic material made by heating substances, generally including materials such as kaolinite, in a kiln to temperatures between 1,200 and 1,400 °C. The strength and translucence of porcelain, relative to other types of pottery, arises mainly from vitrification and formation of the mineral mullite within the body at these high temperatures. Though definitions vary, porcelain can be divided into three main categories: hard-paste, soft-paste, and bone china. The category that an object belongs to depends on the composition of the paste used to make the body of the porcelain object and the firing conditions.
Earthenware is glazed or unglazed nonvitreous pottery that has normally been fired below 1,200 °C (2,190 °F). Basic earthenware, often called terracotta, absorbs liquids such as water. However, earthenware can be made impervious to liquids by coating it with a ceramic glaze, which the great majority of modern domestic earthenware has. The main other important types of pottery are porcelain, bone china, and stoneware, all fired at high enough temperatures to vitrify.
Tiles are usually thin, square or rectangular coverings manufactured from hard-wearing material such as ceramic, stone, metal, baked clay, or even glass. They are generally fixed in place in an array to cover roofs, floors, walls, edges, or other objects such as tabletops. Alternatively, tile can sometimes refer to similar units made from lightweight materials such as perlite, wood, and mineral wool, typically used for wall and ceiling applications. In another sense, a tile is a construction tile or similar object, such as rectangular counters used in playing games. The word is derived from the French word tuile, which is, in turn, from the Latin word tegula, meaning a roof tile composed of fired clay.
An oven is a tool which is used to expose materials to a hot environment. Ovens contain a hollow chamber and provide a means of heating the chamber in a controlled way. In use since antiquity, they have been used to accomplish a wide variety of tasks requiring controlled heating. Because they are used for a variety of purposes, there are many different types of ovens. These types differ depending on their intended purpose and based upon how they generate heat.
Stoneware is a rather broad term for pottery or other ceramics fired at a relatively high temperature. A modern technical definition is a vitreous or semi-vitreous ceramic made primarily from stoneware clay or non-refractory fire clay. Whether vitrified or not, it is nonporous ; it may or may not be glazed. Historically, around the world, it has been developed after earthenware and before porcelain, and has often been used for high-quality as well as utilitarian wares.
A fire brick, firebrick, or refractory is a block of ceramic material used in lining furnaces, kilns, fireboxes, and fireplaces. A refractory brick is built primarily to withstand high temperature, but will also usually have a low thermal conductivity for greater energy efficiency. Usually dense firebricks are used in applications with extreme mechanical, chemical, or thermal stresses, such as the inside of a wood-fired kiln or a furnace, which is subject to abrasion from wood, fluxing from ash or slag, and high temperatures. In other, less harsh situations, such as in an electric- or natural gas-fired kiln, more porous bricks, commonly known as "kiln bricks", are a better choice. They are weaker, but they are much lighter and easier to form and insulate far better than dense bricks. In any case, firebricks should not spall, and their strength should hold up well during rapid temperature changes.
Cement kilns are used for the pyroprocessing stage of manufacture of portland and other types of hydraulic cement, in which calcium carbonate reacts with silica-bearing minerals to form a mixture of calcium silicates. Over a billion tonnes of cement are made per year, and cement kilns are the heart of this production process: their capacity usually defines the capacity of the cement plant. As the main energy-consuming and greenhouse-gas–emitting stage of cement manufacture, improvement of kiln efficiency has been the central concern of cement manufacturing technology. Emissions from cement kilns are a major source of greenhouse gas emissions, accounting for around 2.5% of non-natural carbon emissions worldwide.
Cement clinker is a solid material produced in the manufacture of Portland cement as an intermediary product. Clinker occurs as lumps or nodules, usually 3 millimetres (0.12 in) to 25 millimetres (0.98 in) in diameter. It is produced by sintering limestone and aluminosilicate materials such as clay during the cement kiln stage.
This is a list of pottery and ceramic terms.
A raw mill is the equipment used to grind raw materials into "rawmix" during the manufacture of cement. Rawmix is then fed to a cement kiln, which transforms it into clinker, which is then ground to make cement in the cement mill. The raw milling stage of the process effectively defines the chemistry of the finished cement, and has a large effect upon the efficiency of the whole manufacturing process.
Lightweight expanded clay aggregate (LECA) or expanded clay (exclay) is a lightweight aggregate made by heating clay to around 1,200 °C (2,190 °F) in a rotary kiln. The yielding gases expand the clay by thousands of small bubbles forming during heating producing a honeycomb structure. LECA has an approximately round or potato shape due to circular movement in the kiln and is available in different sizes and densities. LECA is used to make lightweight concrete products and other uses.
The term Brick Expressionism describes a specific variant of Expressionist architecture that uses bricks, tiles or clinker bricks as the main visible building material. Buildings in the style were erected mostly in the 1920s, primarily in Germany and the Netherlands, where the style was created.
Three-phase firing or iron reduction technique is a firing technique used in ancient Greek pottery production, specifically for painted vases. Already vessels from the Bronze Age feature the colouring typical of the technique, with yellow, orange or red clay and brown or red decoration. By the 7th century BC, the process was perfected in mainland Greece enabling the production of extremely shiny black-slipped surfaces, which led to the development of the black-figure and red-figure techniques, which dominated Greek vase painting until about 300 BC.
Structural clay tile describes a category of burned-clay building materials used to construct roofing, walls, and flooring for structural and non-structural purposes, especially in fireproofing applications. Also called building tile, structural terra cotta, hollow tile, saltillo tile, and clay block, the material is an extruded clay shape with substantial depth that allows it to be laid in the same manner as other clay or concrete masonry. In North America it was chiefly used during the late 19th and early 20th centuries, reaching peak popularity at the turn of the century and declining around the 1950s. Structural clay tile grew in popularity in the end of the nineteenth-century because it could be constructed faster, was lighter, and required simpler flat falsework than earlier brick vaulting construction. Each unit is generally made of clay or terra-cotta with hollow cavities, or cells, inside it. The colors of terracotta transform from gray to orange, red, yellow, and cream tones. This is due to an effect of the firing process which hardens the clay so it can be used for structural purposes. The material is commonly used in floor arches, fireproofing, partition walls, and furring. It continues to be used in Europe to build fire-resistant walls and partitions. In North America the material has largely been replaced by concrete masonry units.
Dutch brick is a small type of yellow brick made in the Netherlands, or similar brick, and an architectural style of building with brick developed by the Dutch. The brick, made from clay dug from river banks or dredged from river beds of the river IJssel and fired over a long period of time, was known for its durability and appearance.
Ceramic art is art made from ceramic materials, including clay. It may take forms including artistic pottery, including tableware, tiles, figurines and other sculpture. As one of the plastic arts, ceramic art is one of the visual arts. While some ceramics are considered fine art, such as pottery or sculpture, most are considered to be decorative, industrial or applied art objects. Ceramics may also be considered artefacts in archaeology. Ceramic art can be made by one person or by a group of people. In a pottery or ceramic factory, a group of people design, manufacture and decorate the art ware. Products from a pottery are sometimes referred to as "art pottery". In a one-person pottery studio, ceramists or potters produce studio pottery.
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