How Bricks Are Made

Did you know that bricks are one of the oldest building materials? They are still commonly used today. You’ll see them on houses, patios, walls, and even DIY fireplaces. Have you ever stopped to wonder how they are created? The Orlando masonry experts at Bedrock have explained each step below.

Step One: Bricks are formed from harvested shale that is known as a lightweight sedimentary rock made from clay or mud. Shale is dug up and then left out in the open for two years to weaken its structure so it can be more easily ground up in the brick factory.

Step Two: The shale is transported to the masonry and ground up with a steel wheel into a fine powder.

Step Three: The shale powder is then mixed with water which forms a brown paste. After mixed thoroughly, the paste is shaped by being pushed through a rectangular opening by an extruder. The long rectangular paste formation is called a slug, and it comes out in one long segment.

Step Four: It is at this point in the process that the bricks get styled based off of a design. If the slug is fired as is, the resulting bricks will have their common red color, but if another color is preferred, then the slug is covered with a powdered mineral like iron or zinc that will give them a different color. After colored (or not) the slug is then given a textured design with a roller. After the desired look is applied, they are ready for cutting.

Step Five: The slug is cut by a knife and separated into standard brick sizes. Next, the bricks are stacked gently. It’s important to stack them gently because they need to be fired as a finishing touch.

Step Six: After being cut the bricks go into a heated drying room. Although the water in the bricks naturally evaporates, the drying room is meant to speed up the process. After enough water has been extracted, the bricks are fired in the kiln. After one and a half days pass, a quality check is required to ensure they are ready to be shipped out.

So next time you see a brick, you’ll know how it came to be. Bricks are a great material, and if you are ever in need of them you can always find some at the Orlando masonry, Bedrock!