Fig. 44 - CHEAP WOODEN MACHINE.
The workmen must attend well to the degree of moisture of the clay which is put into the machine. It should be dry enough to show no undue moisture on its surface as it comes out of the die-plate, and sufficiently moist not[pg 182] to be crumbled in passing the edge of the mould. The clay for small (thin) tiles must, necessarily, be more moist than that which is to pass through a wider aperture; and for the latter there may, with advantage, be more sand in the paste than would be practicable with the former.
After the tiles are cut into lengths, they are removed by a set of mandrils, small enough to pass easily into them, such as are shown in Fig. 45, (the number of fingers corresponding with the number of rows of tiles made by the machine,) and are placed on shelves made of narrow strips sawn from one-inch boards, laid with spaces between them to allow a free circulation of air.
Fig. 45 - MANDRIL FOR CARRYING TILES FROM MACHINE.
Drying and Rolling.—Care must be taken that freshly made tiles be not dried too rapidly. They should be sheltered from the sun and from strong winds. Too rapid drying has the effect of warping them out of shape, and, sometimes, of cracking the clay. To provide against this injury, the drying is done under sheds or other covering, and the side which is exposed to the prevailing winds is sometimes boarded up.
For the first drying, the tiles are placed in single layers on the shelves. When about half dried,—at which time they are usually warped more or less from their true shape,—it is well to roll them. This is done by passing through them a smooth, round stick, (sufficiently smaller than the bore to enter it easily, and long enough to project five or six inches beyond each end of the tile,) and,—holding one end of the stick in each hand,—rolling them carefully on a table. This operation should be performed when the tiles are still moist enough not to be broken by the slight bending required to make them straight. After rolling, the tiles may be piled up in close layers, some[pg 183] four or five feet high, (which will secure them against further warping,) and left until they are dry enough for burning,—that is, as dry as they can be made by exposure to the air.
Burning.—Tiles are burned in kilns in which, by the effect of flame acting directly upon them, they are raised to a heat sufficient to melt some of their more easily fusible ingredients, and give to them a stone-like hardness.
Kilns are of various construction and of various sizes. As this book is not intended for the instruction of those who are engaged in the general manufacture of tiles, only for those who may find it necessary to establish local works, it will be sufficient to describe a temporary earthen kiln which may be cheaply built, and which will answer an excellent purpose, where only 100,000 or 200,000 tiles per season will be required.