Clay blocks

from Wikipedia, the free encyclopedia
Production of clay blocks in 1000 €: 2012 - 341,454, 2013 - 363,965, 2014 - 373,116, 2015 - 361,065, 2016 - 397,824
Production value of clay blocks without supplementary products. In 2016, the production value increased by over 10 percent compared to the previous year.

Backing bricks are those bricks that are on the inside of a double walled wall . This means that they do not have to meet certain requirements (e.g. frost resistance, weather protection). Backing bricks are used in the construction of external and internal walls in solid construction. The main areas of application are commercial construction (10%), public construction  (10%) and, above all, residential construction  (80%).

Use in Germany

In 2016, 6.1 million m³ of clay blocks with a production value of 398 million euros were produced in Germany.

With a market share of around 45 percent, brick is the most widely used building material in masonry housing. The physical properties of the clay blocks have been continuously improved since the 1990s. The building material was continuously developed; Nowadays, clay blocks enable optimal thermal insulation and use in multi-storey buildings for buildings with up to nine storeys.

Manufacturing

Clay as the basic material for making clay blocks

Quaternary clay material in Estonia
Clay - the basic material of brick manufacture

The building material clay forms the basis of the clay block production. There is a great variety of clay. Clay deposits formed in every geological age. Even today, new clay deposits emerge at river mouths, in valleys or lowlands. This also explains the production sites, which are usually located directly at the clay deposits. The clay is mainly extracted in open-cast mining, only rarely in underground mining.

In the course of the production process, the clay undergoes changes, which are also reflected in a linguistic distinction from “grown soil” to “broken pieces”, the fired finished product.

properties

Despite the open-pore material and the high percentage of holes and the associated excellent thermal insulation properties, brickwork is characterized by its high load-bearing capacity. Once a brick has dried and fired, it has a shape that it retains for its lifetime despite external influences such as heat and cold.

Special bricks are approved for safe building in all earthquake zones.

In the industry, the brick is known as a decathlete. Because the interplay of 10 properties makes it a high-quality building material:

Cold and heat protection

The backing brick has very good thermal insulation properties, depending on the bulk density. It stores heat and thus prevents the apartments from cooling down too quickly in winter when the heating is interrupted. It also offers the best conditions for summer heat protection. It protects against overheating by storing heat and only releasing it into the room after a delay in a weakened form.

Soundproofing

The backing brick ensures very good sound insulation with a type of construction that corresponds to the gross density.

Fire protection

The brick went through the fire while it was burning. As a non-combustible building material of class A1 and with a fire resistance rating of F 90, the clay block meets the highest fire protection requirements.

Moisture protection

The clay block is a natural humidity regulator. Due to its capillary structure, it is able to absorb room moisture, store it and quickly dissipate it again under favorable climatic conditions. It has the lowest manufacturing moisture among the building materials.

longevity

The clay block is characterized by its low bulk density and high strength. Due to its dimensional stability, which is hardly subject to shrinkage or swelling processes, it offers excellent conditions for crack-free walls. It is a good substrate for weather- and frost-resistant facades.

Healthy living environment

The brick is made from the natural raw materials clay, sand and water. According to the Sentinel-Haus® Institute, the tested natural building material brick meets all the criteria that are important for healthy living : "Lowest pollutant emissions, excellent thermal insulation, high soundproofing, very good moisture compensation and protection against the formation of mold."

economics

Due to the good thermal insulation properties, additional external insulation is not required with the monolithic brick construction. After the wall has been erected, all that remains is to apply plaster to complete the building envelope. Due to the high heat storage capacity of massive brick buildings, heating energy costs are saved. Due to the monolithic construction, the property remains maintenance-free for a long time.

Sustainability and lasting value

The brick is recyclable. It can be completely recycled as brick, brick chippings or ground in other product or construction applications or disposed of as normal building rubble . It is sustainable due to its ecologically and physically optimal properties as well as extremely high durability, low life cycle costs and stable value.

Product delineation

The brick is a brick, i.e. a pre-formed element for the production of masonry, which is fired from clay or other clay-containing substances with or without sand or other additives at a sufficiently high temperature to achieve a ceramic bond.

In addition to the type of brick, there are facing bricks , roof tiles and paving clinker .

Backing bricks are used to create external and internal walls, which are protected against the ingress of water as a shell.

Application and products

The definitions of the main types of bricks in accordance with the standards DIN 105-100 and DIN EN 771-1 in conjunction with DIN 20000-401. A distinction is made between block bricks, vertically perforated bricks, flat bricks and supplementary bricks.

Block bricks
Conventionally manufactured brick, which is not ground flat after the firing process and therefore has higher dimensional tolerances.
Vertically perforated brick
LD or HD bricks with perforations of types A, B or W perpendicular to the storage area.
Plan brick
Bricks with particular dimensional accuracy with regard to the brick height, which is usually regulated according to the approval.
Flat brick with insulation material filling
Bricks with particular dimensional stability that are filled with insulation material, have low thermal conductivity and particularly good soundproofing properties and are suitable for single-shell wall structures.
Complementary brick
Masonry bricks with a shape designed for a specific purpose, for example to complete the shape of the masonry. This can be stop and ceiling edge shells, brick shutter boxes and thermal insulation lintels.
Approval tile
Masonry bricks according to general building inspectorate approval, or approval bricks for short, make up the majority of all bricks used. Due to ever shorter innovation cycles, standards are too inflexible to record and regulate short-term product innovations. For this reason, such products are regulated by general building inspectorate approvals by the German Institute for Structural Engineering and published in approval registers. Approval bricks are mostly produced as large-format flat bricks with flat, ground storage areas.

Highly insulating approval bricks for 1- to 4-storey buildings

When building new buildings with a low building height, thermal insulation is the dominant dimensioning criterion. Different manufacturing processes enable bricks to have low thermal conductivity values. Perforated bricks without insulation material offer the highest possible resistance to the flow of heat through a sophisticated hole pattern and thus achieve thermal conductivity values ​​of λ = 0.08 W / (m K). The latest generation of bricks are filled with insulating material and achieve values ​​of λ = 0.07 W / (m K). The fillings are mineral, non-combustible, open to diffusion and consist of hydrophobized perlite or mineral fiber insulation. Despite the open-pore material and the high percentage of holes, brickwork is characterized by a high load-bearing capacity and enables compressive stresses of σ0 = 0.5 to 1.0 MN / m².

Highly insulating approval bricks for exterior walls with high requirements in terms of load-bearing capacity and structural sound insulation

Sound insulation is of particular importance in multi-storey residential buildings and with mixed use . With proper construction and execution, the building code requirements for structural noise protection can be achieved very well with values ​​of 49 to 52 dB.

In the case of multi-storey buildings, there are also higher demands on the load-bearing capacity of the masonry. Special bricks were developed for these types of buildings. With single-layer brick outer walls, they allow compressive stresses between σ0 = 1.15 and 1.9 MN / m².

Production method and processing

Bricks are made from clay, loam or clay-containing masses with or without aggregates . Aggregates such as sawdust, paper traps or polystyrene balls reduce the bulk density, while adding heavy material increases it. The various raw materials and aggregates are appropriately dosed in the raw material processing via feeders and, if necessary, crushed and mixed in the pan mill and rolling mill with the addition of water. In the wall tower or swamp house, even moisture penetration and further mixing (homogenization) is achieved.

After the required consistency has been achieved by adding steam, the clay is strongly compressed under high pressure in an extruder with negative pressure and pressed through a mouthpiece via screw shafts. The mouthpiece specifies the shape of the later brick and whether it has to meet certain requirements without holes or with a certain hole (hole pattern). Through the composition of the clay and the choice of the structure of the hole pattern, parameters such as compressive strength, heat and sound insulation of the later product can be determined.

After the continuous strand has been cut into individual blanks with a single or harp cutter, these are dried in chambers over a period of 1 to 3 days at temperatures of 50 to 100 ° C.

In the tunnel kiln, the clay blanks are fired over several temperature zones. Perforated bricks are fired at temperatures of around 950 to 1050 ° C. At temperatures of around 1100 ° C, one speaks of sintering or melt sintering, in which the surface begins to melt and the clinker is given properties such as particularly high compressive strength, particularly low water absorption capacity, and frost resistance.

In the case of flat bricks that are intended for processing using the thin-bed method, the horizontal joints are ground flat with an accuracy of less than one millimeter after the firing process.

In a further processing step, the properties of plane-ground vertically perforated bricks can be further optimized in terms of heat and sound insulation by filling the air chambers with purely mineral thermal insulation materials such as perlite, mineral fiber insulation panels or loose mineral fiber insulation.

After the quality control, bricks are palletized, wrapped in a weatherproof film, stored and loaded.

The planar bricks and bricks with insulating material filling that are mainly used today "have flat, ground bearing surfaces and allow execution with thin-bed mortar so that the masonry can withstand significantly higher compressive loads."

Depending on the thickness of the masonry, monolithic, i.e. single-shell brick walls are possible. They are usually plastered inside and out; Two-shell constructions with a facing brick are also conceivable for external walls.

Environmental product declaration

Since August 2015 has insulating non-filled and insulation-filled hollow bricks an Environmental Product Declaration (Environmental Product Declaration, EPD) according to ISO 14025 and DIN EN 15804 of the IBU - Institute Construction and Environment. V. , Berlin. These EPDs apply to almost all masonry bricks manufactured in Germany by 90 and 98 percent of the manufacturers grouped together in the masonry brickwork group (AMZ).

future

From 2016 the energy savings regulations in 2014 raises the energy standard for new buildings, both residential and non-residential buildings. Depending on the wall thickness and the planning of the building, all of the KfW efficiency standards promoted up to the passive house can be achieved with bricks in the future without additional insulation. For the new KfW Standard 40 Plus, a significant part of the energy requirement must be generated and stored directly in the building. It is true that a highly insulating building envelope is still important; a KfW assistance is however substantially determined by the use of renewable energy.

The rising construction costs are closely related to the topic of energy efficiency. According to the study "Cost Drivers for Housing Construction" by the Arbeitsgemeinschaft für zeitgemes Bauen e. V. (Arge Kiel) from April 2015, the costs for the construction of an exemplary multi-storey residential building increased from € 983 / m² living space in 2000 to € 1,432 / m² living space in 2014. The shell construction is not one of the cost drivers. In relation to the total construction costs, the share of shell construction in multi-storey residential construction has fallen from 54 to 46 percent. In single-family house construction, it amounts to only around a third of the total construction costs. According to the Federal Statistical Office, prices for material and processing rose by just 1.2 percent between August 2014 and August 2015, while inflation was 1.6 percent. If you look at the increase in performance of clay blocks in terms of statics, heat and noise protection compared to earlier product generations, an economic advantage becomes understandable.

Publications

literature

  • Peter Bachmann, Matthias Lange (Eds.): Build healthily with safety. 2nd Edition. Springer Vieweg, Wiesbaden 2013.
  • W. Bender: Popular errors in the history of brickwork technology. In: ZI. 12/2006.
  • Bundesverband Baustoffe - Steine ​​und Erden e. V. (Ed.), Michael Grömling: Economic portrait of the German building materials industry. Institute of the German Economy Cologne, Berlin 2011.
  • Federal Association of the German Brick and Tile Industry V. (ed.), Erwin Rupp, Günther Friedrich (edit.): The history of brick production. 3. Edition. Bonn 1993.
  • Federal Association of the German Brick and Tile Industry V. (Ed.): From the brick god to the industrial electronics technician - history of brick production from the beginnings to the present day, text / picture / editorial office Willi Bender, Bonn 2004, ISBN 3-9807595-1-2 .
  • Ziegel Zentrum Süd e. V. (Ed.), Michael Pröll: Brick Lexicon Masonry 2014/15. Munich 2014.

Web links

Commons : bricks  - collection of pictures, videos and audio files
Wiktionary: Bricks  - explanations of meanings, word origins, synonyms, translations

Individual evidence

  1. ↑ "Back brick" on www.architektur-lexikon.de
  2. ↑ Federal Association of the German Brick and Tile Industry, quarterly figures 4/2015
  3. ↑ Michael Grömling: Economic portrait of the German building materials industry . Ed .: Bundesverband Baustoffe - Steine ​​und Erden e. V. Institute of the German Economy Cologne, Berlin 2011, p. 30 .
  4. ^ Federal Association of Bricks - Back Bricks. Retrieved June 19, 2019 .
  5. ↑ a b Willi Bender: From the brick god to the industrial electronics technician - history of brick production from the beginnings to today . Ed .: Federal Association of the German Brick and Tile Industry e. V. Bonn 2004, ISBN 3-9807595-1-2 , p. 83 .
  6. ↑ Willi Bender: From the brick god to the industrial electronics technician - history of brick production from the beginning until today . Ed .: Federal Association of the German Brick and Tile Industry e. V. Bonn 2004, ISBN 3-9807595-1-2 , p. 86 .
  7. ↑ Willi Bender: From the brick god to the industrial electronics technician - history of brick production from the beginning until today . Ed .: Federal Association of the German Brick and Tile Industry e. V. Bonn 2004, ISBN 3-9807595-1-2 , p. 109 .
  8. ↑ Willi Bender: From the brick god to the industrial electronics technician - history of brick production from the beginning until today . Ed .: Federal Association of the German Brick and Tile Industry e. V. Bonn 2004, ISBN 3-9807595-1-2 , p. 111 .
  9. ↑ Michael Pröll: Brick Lexicon Masonry 2014/15 . Ed .: Ziegel Zentrum Süd e. V. Munich 2014, p. 14 .
  10. ↑ deformation. (No longer available online.) Archived from the original on July 15, 2013 ; accessed on February 15, 2016 . Info: The archive link was inserted automatically and has not yet been checked. Please check the original and archive link according to the instructions and then remove this notice. @1@ 2Template: Webachiv / IABot / www.wienerberger.de
  11. ↑ TS QUADRAT data sheet 2011. (PDF; 1.22 MB) Retrieved on February 15, 2016 .
  12. ↑ a b c d e Michael Pröll: Brick Lexicon Masonry 2014/15 . Ed .: Ziegel Zentrum Süd e. V. Munich 2014, p. 8 .
  13. ↑ Product advantages - living space brick. Retrieved February 15, 2016 .
  14. ↑ AMz report 2/2002. (PDF; 111 kB) (No longer available online.) Archived from the original on April 29, 2016 ; accessed on February 15, 2016 . Info: The archive link was inserted automatically and has not yet been checked. Please check the original and archive link according to the instructions and then remove this notice. @1@ 2Template: Webachiv / IABot / www.ziegel.de
  15. ↑ Block bricks
  16. ↑ a b Michael Pröll: Brick Lexicon Masonry 2014/15 . Ed .: Ziegel Zentrum Süd e. V. Munich 2014, p. 8th f .
  17. ↑ Wienerberger - backfilled brick. (PDF; 7.08 MB) p. 4 , accessed on February 15, 2016 .
  18. ↑ What are the advantages of masonry bricks with integrated insulation material? Retrieved February 15, 2016 .
  19. ↑ a b Michael Pröll: Brick Lexicon Masonry 2014/15 . Ed .: Ziegel Zentrum Süd e. V. Munich 2014, p. 7 .
  20. ↑ a b 2. Bricks according to general building authority approval. Retrieved March 31, 2016 .
  21. ↑ Bricks - making bricks. Retrieved March 31, 2016 .
  22. ↑ Peter Bachmann and Matthias Lange (eds.): Build healthily with safety . 2nd Edition. Springer Vieweg, Wiesbaden 2013, p. 112 .
  23. ↑ Bricks (filled with insulation). (PDF; 3.1 MB) Retrieved February 15, 2016 .
  24. ↑ Bricks (insulation material unfilled). (PDF; 3.02 MB) Retrieved February 15, 2016 .
  25. ↑ All efficiency house standards are possible with bricks. Retrieved February 15, 2016 .
  26. ↑ Clearly name the horse and rider! Retrieved February 15, 2016 .