In general terms, the process is as follows:—The clay is mixed with sand, or other substances which give it the proper consistency, and is so wetted as to form a plastic mass, to which may be given any desired form, and which is sufficiently stiff to retain its shape. Properly prepared clay is forced through the aperture of a die of the shape of the outside of the tile, while a plug,—held by a support in the rear of the die,—projects through the aperture, and gives the form to the bore of the tile. The shape of the material of the tile, as it comes from the die, corresponds to the open space, between the plug and the edge of the aperture. The clay is forced out in a continuous pipe, which is cut to the desired length by a wire, which is so thin as to pass through the mass without altering the shape of the pipe. The short lengths of pipe are dried in the air as thoroughly as they can be, and are then burned in a kiln, similar to that used for pottery.
Materials.—The range of earths which may be used in the manufacture of tiles is considerable, though clay is the basis of all of them. The best is, probably, the clay[pg 175] which is almost invariably found at the bottom of muck beds, as this is finer and more compact than that which is dug from dry land, and requires but little preparation. There is, also, a peculiar clay, found in some localities, which is almost like quick-sand in its nature, and which is excellent for tile-making,—requiring no freezing, or washing to prepare it for the machine. As a general rule, any clay which will make good bricks will make tiles. When first taken from the ground, these clays are not usually adhesive, but become so on being moistened and kneaded.
It is especially important that no limestone pebbles be mixed with the clay, as the burning would change these to quicklime, which, in slaking, would destroy the tiles. The presence of a limey earth, however, mixed through the mass, is a positive advantage, as in this intimate admixture, the lime forms, under the heat of the kiln, a chemical combination with the other ingredients; and, as it melts more readily than some of them, it hastens the burning and makes it more complete. What is known as plastic clay, (one of the purest of the native clays,) is too strong for tile-making, and must be "tempered," by having other substances mixed with it, to give it a stiffer quality.
The clay which is best for brick-making, contains Silica, and Alumina in about the following proportions:
Silica ... 55 to 75 per cent.
Alumina ... 35 to 25 per cent.
Variable quantities of other materials are usually found in connection with the clay, in its native condition. The most common of these are the following:—
Magnesia 1 to 5 per cent.—sometimes 20 to 30 per cent.
Lime 0 to 19 per cent.
Potash 0 to 5 per cent.