brickyard

A brickyard is a site where bricks are manufactured from clay or shale through forming, drying, and firing. The term is commonly applied to industrial operations producing large quantities, though small craft studios may also be described as brickyards.

Raw materials typically come from nearby clay pits or shale beds. The material is excavated, processed to achieve a uniform texture and plasticity, and blended with additives such as sand or grog to achieve the desired properties. Bricks are formed by extrusion, molding, or pressing, then stacked for drying. Drying reduces moisture content to prevent cracking during firing and can be achieved through natural air drying or mechanical dryers.

Firing is the key step, conducted in kilns that reach high temperatures to harden the bricks. Kilns vary from intermittent, batch-type units to continuous, steady-state systems. Common kiln types include clamp or kiln-stacked setups, Hoffmann continuous kilns, tunnel kilns, and other apparatus designed to control heat, airflow, and fuel use. Firing temperatures typically range around 900 to 1,200 degrees Celsius, producing bricks of various colors and strengths.

Products from brickyards include common bricks for structural use, facing or architectural bricks with higher aesthetic or durability requirements, and specialized bricks such as engineering or interlocking varieties. Brick sizes and profiles vary by region and market.

Economic and environmental factors influence brickyards: proximity to clay sources and transport networks, energy costs, and emissions control. In many regions, old or idle brickyards have been repurposed as industrial heritage sites, while active yards continue to supply construction markets.