Making Bricks

The process of making bricks can be divided into a number of stages.  Each stage will be looked at in turn.

Extracting
the clay
Treating
the clay
Making
the bricks
Distributing
the bricks

Treating the Clay

When the clay has been extracted by the dragline it is still in large pieces, which need to be broken down for easy transport.  The old system used vibrating metal bars called a grizzly to sort out smaller pieces of clay that could go directly onto the conveyor belt.  A kibbler then broke down larger pieces of clay and rejected limestone nodules.

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Kibbler

Kibbler

A Hydraulic Ram is used to remove unwanted rock from the belt

A Hydraulic Ram is used to remove unwanted rock from the belt

Originally the clay was moved by hand or using horses. As the industry became more mechanised the pits became larger and deeper. This meant the clay had to be moved greater distances and up sharper inclines. One initial solution was to use a continuous chain haulage system. This was initially powered by a steam engine and later by electric motors.

 

Chain Haulage at Elstow

Chain Haulage at Elstow

Some works operated a light railway to move the wagons of clay. Coronation and Brogborough pits both had such a railway. Conveyor belts are now used to transport the clay. The conveyor linking Quest Pit to Stewartby Works normally transports about 200 tonnes of clay per hour.  

Locomotive moving trucks, Stewartby Pit 1935

Locomotive moving trucks, Stewartby Pit 1935

Conveyor belt entering the works

Conveyor belt entering the works

The next stage of the operation is to grind the clay into a powder. This operation is carried out in the grinding pans which are fed by huge hoppers.

The grinding pans contain two huge rollers which rotate and crush the clay. Each roller is immensely heavy, it has a steel facing and is filled with concrete. A conveyor belt takes the ground clay to the screens for sorting. There used to be 54 grinding pans at Stewartby, now there are only 8. They have been largely replaced by German made hammer mills. The grinding pans are now only used to grind material that has been rejected by the screens.

Hoppers feeding the grinding pans

Hoppers feeding the grinding pans

Looking down into the grinding pan

Looking down into the grinding pan

After grinding, the clay is sieved. Pieces too large to fit through the mesh are returned to the grinding pans. Several different systems have been used to sieve the clay. Originally rotary screens were used, brushes stopped them becoming clogged with clay. These were replaced with screens made of heated piano wire. The heat stopped the clay sticking to the screens. The present system is a series of four angled vibrating mats called Morganson screens. The sieved clay passes along a conveyor belt to the brick press hoppers.

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