Material rating
20 out of 5 Price
20 out of 5
Practicality
20 out of 5
Appearance
20 out of 5
Ease of manufacture
20 out of 5
Environmental friendliness
final grade
5
5 out of 5
Fireclay is made from white kaolin clay, which is thermally treated to increase heat resistance. After processing in hot ovens, fireclay acquires the properties of stone, which is crushed to form fireclay clay. With its help, they equip any heat-resistant structures, make fire-resistant bricks, and beautiful decorative items.
What is fireclay clay, description
Fireclay clay can be found in stores in the form of dry building mass, which is added to masonry and plaster mortars. Fireclay bricks are also sold. Fired kaolin can be white with creamy tones or gray-brown, depending on the firing.
Compound
Fireclay is made from clay, which contains highly dispersed hydroaluminosilicates. This clay is formed into pieces of any shape or pressed briquettes and fired in special ovens heated to a very high temperature.
There are many recipes for making fireclay mass. Some compositions add more calcined powder, others consist of coarse powder, more water in one mass, etc.
Fireclay also varies in duration and firing temperature. As a result, masses of different colors and textures come out of the ovens.
Fire clay consists of many chemical elements:
- Quartz (Si02);
- Aluminum oxide ceramics (Al2O3);
- Calcium oxide (CaO);
- Potassium oxide (K2O);
- Magnesium oxide (MgO);
- Sodium oxide (Na2O),
- Iron oxide (Fe2O3.
Bentonite clay is a material of natural origin, which is distinguished by the fact that it can be used almost everywhere. Its main component is montmorillonite.
Due to the wide variety of types, clay has found application in many industries and areas of life. Find out what you can make from clay here.
Material composition
The finished material is somewhat similar to stone. You can also find it in powder form. In this case, it is mixed into the solution. Some varieties are also available in brick form. The color of kaolin may vary depending on the manufacturing technology. It can be white with a cream tint, or gray-brown.
The basis is clay with highly dispersed aluminum hydrosilicates. This material can be given any shape, for example, to make briquettes. The firing time and temperature can be different. After this, crushing is carried out and a granular structure is given. The main components of fireclay clay are ::
- calcium oxide;
- quartz;
- compounds of potassium and magnesium.
It also includes sodium and iron in the form of oxides.
Watch an interesting video on how you can make a flower pot from fireclay clay with your own hands:
Technical characteristics and properties
When purchasing fireclay clay, you must make sure that its expiration date has not yet expired and that it has been stored under the correct conditions. Since during long-term storage kaolin loses its properties. Humid air is especially dangerous for it.
Fireclay clay is produced in accordance with GOST - 6137-8 and has the following technical characteristics:
- The average grain size is approximately 2 mm.
- Moisture absorption: for high-burnt fireclay from 2 to 10%, for low-burnt fireclay – up to 25%.
- Humidity – no more than 5%.
- Fire resistance – from 1550 to 1850 °C (depending on the composition);
A package of fireclay clay weighing 20 kg is enough to lay 20-30 bricks. For one cubic meter masonry will need 100 kg of calcined kaolin. The finished solution hardens within two days at an air temperature ranging from + 10 to + 25 ° C.
Fireclay clay can be stored in its original packaging for no more than three years, based on the date of manufacture. Full strength is achieved after 28 days.
Material use options
Fire bricks are made from clay. It is used for the preparation of plaster and masonry mortars. The third application option is making crafts, souvenirs, and decorative dishes.
Heat resistant brick
This piece building material is sold ready-made. It will not be possible to make refractory bricks yourself at home, since it is difficult to maintain geometric accuracy and ensure the required firing temperature. Bricks for stoves are marked with the letter “Ш”. It is much more expensive than usual, so it is used only for laying the firebox. It is more profitable to make the rest of the furnace from ordinary ordinary bricks.
Masonry mortar is prepared from burnt kaolin, since it has the same coefficient of expansion as fireclay bricks. Solution consumption is about 30 liters per 100 pieces.
Plaster mixture
The plaster mixture is made from chamotte , just like from other dry raw materials. The consistency is like thick sour cream. The mixture is used for primary finishing, as well as for restoring areas where the putty has peeled off or cracked. Components for mixing the solution:
- 7 kg of quarry sand;
- 2 kg of fireclay clay;
- 1 kg of cement.
Take enough water to achieve the desired thickness. For application you need to use 2 spatulas, medium and wide. The solution is applied from bottom to top, leveling and picking up excess. It is better to smooth out unevenness immediately. When the solution begins to harden, this will be more difficult to do.
The thickness of the plaster layer should not exceed 2−3 mm. The mixture is applied to dry brick. When the entire surface is plastered, it is left for final hardening. How long this takes depends on the type of mixture. Usually the manufacturer indicates the hardening time on the packaging. The finishing coating begins when the plaster layer is completely dry.
Working with masonry mixture
The solution is mixed from a mixture of clay and sand in a 1:1 ratio. It is convenient to use a 40-liter tank - it is easier to mix the mass in it. The consistency is checked as follows: put a little mixture on a trowel and tilt it. The finished mass should not drain, but slide. If it stays in a motionless lump, you need to pour in more water, and when the mixture is too liquid, add equal parts sand and clay.
The laying is done as usual, trying to ensure that the mortar completely fills the horizontal and vertical joints. If depressions remain, they will subsequently need to be sealed with a putty mixture based on the same clay. When applying the masonry mixture, it is important to provide ventilation in the room and ensure that particles of the solution do not get on the skin and especially in the eyes.
Methods of using fireclay clay
Fireclay clay is used to make dry mixtures for preparing plaster and masonry mortars and creating fireproof bricks.
Furnace laying
When building a stove or fireplace, many stove makers try to use heat-resistant bricks made from a clay-fireclay mixture. When choosing it, you should pay attention to the labeling; the letter “Ш” should be indicated on the packaging. Since such a brick is much more expensive, only the firebox is built from it, and the rest of the stove is laid out from ordinary red brick.
Fireclay bricks must also be laid on refractory clay, which has the same expansion coefficients as bricks. For 100 bricks you will need approximately three buckets of mortar.
The video will tell you about the specifics of laying bricks on fireclay clay:
Plaster
Working with fireclay clay is similar to the familiar plastering process. To finish the stoves, you do not need any specific tools; you only need two spatulas - one large and the other medium. They will be quite sufficient for high-quality plastering of stoves.
When applying the solution, do not forget to pick up any spilled drops with a spatula and smooth out any unevenness in a timely manner. The layer should be no thicker than 1 - 2 mm. There is no need to wet the fireclay brick with water. At the end of the work, allow the plaster to dry; the required drying time can be found on the packaging of the mixture. Finishing work can only begin after complete drying.
Other products made from fireclay clay
Designers really like this fire-resistant, especially durable material for its special texture and discreet beauty. Craftsmen make figurines, ceramic dishes, tiles and other things from it. Products made from fireclay clay can decorate the most sophisticated interior.
And all thanks to the fact that fireclay clay, when impurities are added to it, becomes a very plastic material. They also love it for its environmental friendliness, because fireclay clay does not contain toxic impurities. To make artistic ceramics, they take plastic clay of different compositions and add fireclay chips to it. Its share is approximately 40%.
To make a product from fireclay clay, a ceramic artist first develops a sketch. Then they make a mold and fill it with fireclay clay, after which it is sent to dry. The product must dry naturally for a long time so that its geometric shapes are not disturbed.
Examples of using fireclay clay in creativity
Fireclay clay figurine No. 1
Fireclay clay figurine No. 2
Fireclay clay figurine No. 3
Fireclay clay figurine No. 4
Fireclay clay figurine No. 5
Fireclay mortar
Intended for the production of mortar, which is used in the process of constructing fireplaces and stoves. Suitable exclusively for fireclay bricks. Fireclay mortar msh 28 and brick have an almost identical structure. After just a few fires, they form a strong natural connection with each other. As a result of its use, you will receive a high-quality fireplace or stove that will serve you for several decades.
The material consists of ground powder and refractory clay. The composition can withstand up to 2000°C. This is an environmentally friendly material that does not emit toxic substances when heated, unlike sand-lime brick, for example.
Fireclay mortar, being a fire-resistant material (able to withstand exposure to open fire without restrictions), is in great demand in a variety of fields. In everyday life it is used for laying fireplaces and stoves as a mortar. An interesting fact is that even in kilns that are used for firing bricks, the product in question is used.
It is extremely easy to use and is manufactured on site by the builder himself. Even a beginner can handle this. The material is available to everyone. I'm pleased with the excellent value for money. It is ideal for work at home.
In addition to the construction of stoves and fireplaces, the mixture is used in metallurgy for the production of steel ladles. In a variety of areas it is used for coating surfaces that will be subject to significant thermal loads.
Instructions for use, consumption of solution, how long it takes to dry
Working with fireclay clay is not easy; many beginners have problems: the masonry turns out to be fragile, cracks appear on the plaster and it crumbles. This happens because when fired, kaolin clay almost completely loses its plastic properties, and when mixing the solution, it needs to regain its plasticity. To do this, add special glue or ordinary quartz sand to the solution.
How to use and breed
Dilute fireclay powder with ordinary water. The proportions are taken depending on the further use of the resulting solution.
How to prepare plaster mortar
- Take a pack of fireclay powder.
- We put it in a special container
- Gradually add water until the powder is completely covered with water.
- After this, leave the diluted clay for at least three days.
- After three days we make the final batch.
- Add quartz sand if the solution is liquid; or water if thick.
- Mix thoroughly by hand or with a special drill.
The finished fireclay solution should have the consistency of thick sour cream, then it will not drain and will stick well to the surface. To speed up the setting time of the solution, you can add cement to it, no more than 2 kg per package of fireclay clay.
You can purchase a composition for instant mixing, which does not need to be infused for three days, but its price is several times higher. PVA construction adhesive is added to both compositions. Sometimes they are reinforced with fiberglass. The finished solution can be applied to the surface using spatulas.
Dilute the mixture in limited quantities, since the hardening time is 48 hours.
How to mix mortar for laying bricks with your own hands
Fireclay clay is diluted with sand and water in a large container; you can take a 10-15 liter tank for this. It is more convenient to mix the solution. Experienced stove makers recommend checking the readiness of the solution by scooping it up with a trowel. If it does not flow and does not stick to the trowel, but slowly slides along it, leaving no traces, the solution is ready for use.
When pressed with a brick, it should completely fill the unevenness of the masonry.
Although fireclay clay is safe, when mixing it, you must take precautions so that the solution does not accidentally get on your face. The work area must have good ventilation.
The video shows how you can check the quality of the prepared mortar before starting masonry:
Preparing the necessary materials
First of all, it is necessary to dwell on one point. Thanks to technological progress and the widespread production of building materials, there is currently one technique using which it is not difficult to prepare clay for laying a stove.
The technology is suitable for those people who do not have practical experience in this area, as well as for those who decided to invest once, build a brick structure in their home and never worry about it again.
We are talking about a wide range of ready-made masonry mixtures. They are available for free sale and are packaged in branded bags. All you need to do is purchase the required amount of material and, using the recommendations on the packaging, dilute it correctly.
The disadvantage is that such a solution for laying a stove is not cheap, and if it is prepared incorrectly, it will be impossible to use, and this is an additional expense. Knowledge in the field of traditional creation of masonry mixture will help you save.
First of all, it will be necessary to obtain clay of the type that is available in a particular region. It will be most convenient to stock up on it in those places where mining has already been carried out on the ground, in ravines or under the river coastline.
After the raw materials have been extracted in the required quantity, they should be transported to the place where the structure is supposed to be erected. Fireclay clay is poured into a prepared container and filled with water. Liquids and material should be taken in a ratio of 1:4 according to volume. Soaking lasts for 48 hours. When the time is up, you will need to mix the mass into a homogeneous consistency. This process is most easily accomplished using a construction mixer rather than tinkering with your own hands.
The hammer drill makes the job much easier
Next, you need to strain the mass through a mesh with cells measuring 3x3 mm, which will make it possible to rid the material of various impurities and stones. Unfortunately, it is almost impossible to obtain sand in the same way. Firstly, it lies deep, and secondly, it can be punishable by administrative liability, so it is better to buy it legally.
Good to know: What should be the height of the firebox in the furnace, we study the dependence on the type of fuel
A high-quality solution can only be made if you use dry sand, preferably pre-cleaned. Adding wet material is not acceptable, so if it gets wet, it needs to be given time to dry. When the mass is dry, it is also sifted through a mesh with cells of about 1.5 mm.
Once you have figured out what fireclay mortar is, and have also prepared all the components, you can begin the mixing procedure.
