How It’s Made: Clay Thin Brick

Words: Allison Goley
Photos: General Shale

Clay thin brick is a versatile alternative to traditional full brick. It comes in numerous colors and styles and offers something for every design preference. Thanks to the lighter weight, it is designed to reach spaces full brick cannot. From floors to ceilings and everywhere in between, thin brick is perfect for both interior and exterior applications.

Typically ranging in thickness from ½” to 1”, thin brick is crafted through a variety of manufacturing methods that each impart unique characteristics. Though they maintain the same fundamental composition as full brick (clay and shale), the process of creating thin brick deviates from full brick manufacturing in key steps depending on the technique used. Whether extruded or saw-cut from full brick, each method offers distinct advantages in terms of appearance and its ability to match corresponding full brick products. Understanding these processes not only highlights the craftsmanship behind thin brick production but also reveals the considerations necessary for achieving visual consistency when designing with brick.

The Natural Origins

Just like traditional full brick, clay thin brick is made from a mixture of clay and shale—originating as the very earth beneath our feet. The process of preparing the clay used to make thin brick is also much the same. In some cases, the method of creating thin brick begins to differ from full brick during the extrusion step. In other cases, thin brick is made by simply cutting a thin slice off a fired full brick.

Thin Brick Extrusion

Just like extruded full brick, which is sometimes called “wirecut,” this process produces a thin brick with clean, straight edges all around. These fit perfectly with more modern, sleek home designs.

The process also begins just like that of full brick, with clay that is fed into a pug mill to be thoroughly mixed. From there, the clay runs through an extruder where the air is removed as the material is condensed. However, the next steps are different depending on whether the brick is intended to have a slip or sand on the face to create color and texture.

When creating thin brick with no slip or sand coating, the clay will pass through a die that is shaped for a full brick. This die has three wires running across it so that the column of clay is cut into standard or custom sized pieces that are essentially sitting atop one another. These cut pieces then travel together down the conveyor to the reel cutter, where they are cut again to the desired width. This “green” (or unfired) brick is then stacked in groups of four onto the kiln car to be dried and fired. When they come out of the kiln, plant workers tap them with a ball-peen hammer to separate the four pieces.

When thin brick requires slip or sand coating, only the side of the clay with this coating can be used as the face. The clay is extruded as thin as possible (usually between ¾” to ½” thick instead of the 3 5/8” of full brick) and then cut to produce individual thin brick that are roughly 2 ¼” wide and 7 5/8” long.

It is slightly more difficult to match extruded thin brick to corresponding full bed colors than thin brick that are only saw cut from full brick. Even if the very same material was used in both processes, the slight differences in the process can cause the full and thin brick to have different characteristics and coloring. The sheer fact that thin brick production requires less clay to be fired at once can cause it to react differently in the kiln than that of a full brick.

While some brick manufacturers, including General Shale, offer corresponding full and thin brick products that have been manufactured through extrusion, they are sold with the intent to be corresponding rather than identical.

Kiln-Flashed Thin Brick Flats Process

To produce thin brick flats that have been kiln-flashed, manufacturers often use the kerf or “split-tile” process. It functions similarly to extrusion but involves a few extra steps. In the end, it produces thin brick that is smooth on its face with clean, straight edges. However, the back of each thin brick is “keyed,” which appears as ridges or grooves along the back of the brick. This leads to improved adhesion when the thin brick is placed on a surface with mortar or adhesive.

In this method, the clay is extruded vertically (which looks like the brick is standing up). The clay passes through a reel cutter, also known as a “wire cutter,” to be cut into the necessary width. “Kerfs,” or small sections of material, are also removed from the center of the thick ribbon—similar to the core holes of a full brick. The goal is to remove as much material as possible while still ensuring the green brick won’t fall apart. This creates what appears to be a full brick with two faces that are joined together by kerfed cross-webbing. Removing this material makes it easier to break into two distinct thin brick pieces at the end of the process.

The brick is dried and fired in a kiln while still connected with cross-webbing. From there, the brick is stacked onto a pallet to be sent to the grinding department where it receives both length and edge grinding. Next, it is manually stacked back onto a conveyor to be split into two different thin bricks. The process of splitting the two bricks is done using a hydraulic press tile splitter that presses on the cross-webbing just enough to snap them. The brick is kerfed so that, when split, the two thin bricks break apart perfectly, leaving ridges on the back side of the brick. As with all unused product, those pieces of clay that created the cross-webbing (often called “pencils”) holding the two thin bricks together are broken off and sent along a conveyor to be ground up and reused.

Saw Cut Thin Brick Flats

Some thin brick products are produced by cutting a thin piece off the face of a fired full brick with a saw.

In this method, full brick is produced as normal and sent along another conveyor to either be stacked and sold as is or cut into thin brick. Water is sprayed onto the brick while the saw cuts off a slice of the brick’s face to reduce the amount of dust created. The unused portion of the brick is ground up and sent back into the manufacturing process, and, often, the dirty water is also sent through a filtering process to be recycled.

Most manufacturers only use the face of the brick since the coating and color are typically only applied to that side. Each thin brick is always intended to face one way when applied to its intended surface.

Thin brick that features textured or rumbled edges have likely been produced using this method. To create a thin brick that appears aged, full brick is dried and fired before a conveyor sends the brick into a rumbler. This machine causes the brick to bump against one another, chip off small pieces of the corners, and knock off some of whatever coating is on the brick. This creates an aged, historic appearance. Once they pop out of the rumbler, the brick is sent along another conveyor to either be stacked and sold as is or cut into thin brick using the method described above.

The clearest benefit of this method is the ability to match full and thin brick products exactly, since this process literally uses the exact same brick for both. It is also the only way to achieve a distressed look on a thin brick. If the thin brick itself were put into the rumbler, it would simply break and crumble into pieces, as something so thin couldn’t handle the amount of force.

Thin Brick Corners and Edge Caps

Each of these processes can produce thin brick flats, corners, and edge caps. In some cases, creating a corner requires both automated and manual processes. Corner units may be extruded or assembled (often mitered) by adhering multiple units. The saw-cut process creates a matching corner unit by simply cutting both the face and one side off a brick in one L-shaped piece. Similarly, flashed corners are first sent through the extruder as a full brick and kerfed so that the corner can be easily cut. Once they are dried and kiln-fired, they are sent to the grinding room for both length and end grinding. Next, they are sent to the wet saw where the saw cuts along the kerfs to remove the corner piece from the full brick. All unused material is ground up to be reused.

Edge caps, or finishing details often used on the tops of walls or piers, are made in much the same way. After passing through the reel cutter to be cut to the desired length, the edge cap is sent to the plant’s shape room where employees manually cut the face and top off a green, unfired brick before it is sent to be dried and kiln fired.

A Style and Solution for Everyone

Clay thin brick offers a practical and visually appealing solution for achieving the timeless look of traditional masonry with added versatility and reduced weight. Whether produced through traditional extrusion, the kerf or “split-tile” process, or saw-cutting, each method has its own unique benefits and produces distinct styles of thin brick. Understanding the nuances of these manufacturing techniques allows architects, builders, and homeowners to make informed choices based on aesthetic goals and installation needs. As thin brick continues to grow in popularity, its diverse production methods ensure there’s a style and solution suited to every project.

How It’s Made: Clay Thin Brick

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