The influence of phosphate on the properties of clay bricks

The fabrication, properties and composition of heated phosphate-bonded clay bricks are reported. The strength of phosphate-bonded clay bodies is shown to be related to the equilibrium pH of the clay mix. The highest strengths were obtained for mixes with equilibrium pH 7 fired at 500°C which gave a modulus of rupture 60% higher than the unmodified clay heated under similar conditions but at 800°C firing temperature. The phosphate-bonded products were also of low porosity and improved dimensional stability. An insight into the probable mechanism of strength development of the heated product has been obtained from XRD, SEM and DSC studies. The results show that the properties of the phosphate-bonded clay bodies are critically affected by new mineral phases resulting from the reactions of phosphates with clay which subsequently undergo physico-chemical changes above 550°C.