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ILLINOIS  GEOLOGICAL 
SURVEY  LIBRARY 


" 


?  ^/?/?j 


STATE  OF  ILLINOIS 

DEPARTMENT  OF  REGISTRATION  AND  EDUCATION 


Illinois  Clay  Resources  for 
Lightweight  Ceramic  Block 


W.  Arthur  White 
Ned  R.  O'Brien 


ILLINOIS  STATE  GEOLOGICAL  SURVEY 
John  C.  Frye,  Chief  URBANA 


CIRCULAR  371 


1964 


Digitized  by  the  Internet  Archive 

in  2012  with  funding  from 

University  of  Illinois  Urbana-Champaign 


http://archive.org/details/illinoisclayreso371whit 


ILLINOIS  CLAY  RESOURCES  FOR 
LIGHTWEIGHT  CERAMIC  BLOCK 

W.  Arthur  White  and  Neal  R.  O'Brien 


ABSTRACT 

Seven  samples  of  clays  and  shales  from  Illinois  were 
tested  to  determine  their  bonding  properties.  The  clay  mate- 
rials are  composed  of  illite,  kaolinite,  montmorillonite,  chlo- 
rite, or  mixed-layer  clay  minerals.  The  materials  were 
ground,  mixed  with  various  percentages  of  water  and  light- 
weight shale  aggregate,  molded  into  blocks  that  measure 
8"  x  8"  x  8",  and  fired  to  temperatures  of  1850°  to  1900°F. 
Compressive  strengths  were  then  determined. 

A  mixture  of  20  parts  clay  to  80  parts  aggregate,  with 
16  pounds  of  water  per  100  pounds  of  mix,  appeared  to  give 
optimum  results.  Blocks  made  with  this  composition  had  com- 
pressive strengths  greater  than  1,  000  pounds  per  square  inch. 
Blocks  with  the  greatest  compressive  strength  generally  were 
obtained  from  the  materials  that  contained  abundant  montmoril- 
lonite and  mixed-layer  clay  minerals. 


INTRODUCTION 

Over  the  last  century,   there  have  been  various  attempts  to  make  lightweight 
ceramic  products.    A  lightweight  aggregate  was  patented  as  early  as  1875,   but  it  was 
about  forty  years  later,  when  Stephen  Hayde  built  the  first  Haydite  plant  near  Kansas 
City,   that  the  manufacture  of  lightweight  aggregate  from  shale  was  advanced  most 
significantly.     Until  the  middle  1940's,  the  industry  developed  slowly,   but  since  the 
end  of  World  War  II,   there  has  been  increasing  interest  in  the  uses  of  lightweight 
aggregate  in  the  building  industry.    Lightweight  aggregate  and  Portland  cement  have 
been  used  as  a  binder  for  concrete  blocks  and  poured  concrete  floors  and  walls. 

Bell  and  McGinnis  (1951)  first  developed  a  large,   lightweight  ceramic  build- 
ing block.    They  used  a  sintered  lightweight  aggregate  made  from  clay  materials 
bonded  with  clay.    These  blocks,  which  were  made  on  a  concrete  block  machine, 
measured  8"  x  8"  x  16",  weighed  approximately  25  pounds,   and  had  compressive 
strengths  of  1,700  pounds  per  square  inch.     Bell  and  McGinnis  concluded  that: 

-1- 


2  ILLINOIS    STATE    GEOLOGICAL    SURVEY    CIRCULAR    371 

"(1)  Clay  building  tile  having  only  slight  firing  shrinkage  and  essentially  no  drying 
shrinkage  can  be  made;  (2)  these  tile  may  be  dried  and  fired  very  rapidly  without 
damage;  (3)  a  wide  range  in  the  physical  properties  of  these  tile  may  be  obtained  by 
proper  selection  and  blending  of  the  clays  and  aggregates  used."    Caruso  (1959), 
Moffitt  (1961),   and  Robinson  (1961;  1962)  have  discussed  the  fabrication  of  light- 
weight clay  bonded  block. 

Most  of  the  papers  mentioned  above  were  interested  in  the  lightweight  ceramic 
block  as  a  finished  product.  The  purpose  of  this  investigation  is  to  study  the  bond- 
ing properties  of  various  clay  minerals  in  Illinois,  after  being  fired,  and  to  describe 
possible  locations  of  clay  materials  that  would  be  useful  in  the  manufacture  of  light- 
weight ceramic  block.  In  many  respects,  however,  the  finished  products  and  raw 
materials  cannot  be  considered  separately. 

Acknowledgments 

The  authors  wish  to  express  their  thanks  to  Messrs.  Poole  and  Rybicki  of 
Chisholm,   Boyd,   and  White  Company  for  pressing  some  of  the  blocks;  to  Mr.  R.  E. 
Fieldbinder  of  Nelsen  Concrete  Culvert  Company  for  making  available  the  steel 
pallets  and  the  pallet  rack  for  drying  the  block;  and  to  Mr.  Gil  Montgomery  of  the 
Minerva  Company  for  furnishing  the  fluorspar  used  in  the  study. 

The  authors  are  indebted  to  Professors  G.  W.  Hollon  and  C.  E.  Kesler,   Uni- 
versity of  Illinois,  who  supervised  the  test,   and  to  Dr.  R.  E.  Grim,   University  of 
Illinois,   and  Dr.  H.  E.  Risser,   Illinois  State  Geological  Survey,   for  critically 
reading  the  manuscript  and  making  helpful  suggestions. 


STRATIGRAPHIC  OCCURRENCE  OF  CLAY  AND  SHALE 

In  Illinois,   clays  and  shale  that  can  be  used  in  the  manufacture  of  clay  bonded 
blocks  range  in  age  from  Ordovician  to  Pleistocene.     Figure  1  shows  the  outcrop 
areas  of  the  bedrock  clay  and  shale  deposits  that  range  in  age  from  Ordovician  through 
Tertiary;  figure  2  shows  the  areas  where  refractory  clays  crop  out;  and  figure  3 
shows  the  areas  of  glacial  tills  and  residual  clays.    The  clays  and  shales  crop  out 
along  stream  valleys,   in  highway  and  railroad  cuts,   and  in  strip  mines.     Clay  and 
shale  deposits  that  may  be  used  as  bonding  materials  in  the  manufacture  of  light- 
weight building  block  occur  in  several  stratigraphic  units.    Their  relative  ages  are 
shown  in  the  following  list. 

Cenozoic  Era 

Quaternary  System 
Pleistocene  Series 

Wisconsinan  Stage 
Illinoian  Stage 
Kansan  Stage 
Tertiary  System 
Paleocene  Series 


CLAY    RESOURCES    FOR    LIGHTWEIGHT    CERAMIC    BLOCK  3 

Porters  Creek  Formation 
Mesozoic  Era 

Cretaceous  System 
Paleozoic  Era 

Pennsylvanian  System 

Mattoon  Formation 
Bond  Formation 
Modesto  Formation 
Carbondale  Formation 
Spoon  Formation 
Abbott  Formation 
Caseyville  Formation 
Mississippian  System 
Chesterian  Series 
Valmeyeran  Series 

Warsaw  Formation 
Kinderhookian  Series 
Hannibal  Group 

Grassy  Creek  Formation 
Ordovician  System 

Maquoketa  Group 
Scales  Formation 

Orchard  Creek  Shale 

Ordovician  Shales 

Maquoketa  Shale 

Maquoketa  Shale  crops  out  in  Alexander,   Calhoun,   Carroll,  Grundy,   Jersey, 
Jo  Daviess,  Kane,  Kankakee,   Kendall,   LaSalle,   Lee,   Monroe,   Ogle,   Stephenson, 
and  Union  Counties.    The  colors  of  the  Maquoketa  Shale  (Rubey,  1952,  p.  22)  may 
be  bluish  gray,  blue,  green,   buff,  tan,  red,   maroon,   purple,   lavender,   or  white. 
The  shale  may  range  from  massive  to  fissile.    The  lithology  ranges  from  an  argilla- 
ceous dolomite  to  a  slightly  calcareous  shale,  which  may  have  a  noncalcareous 
portion  near  the  top.     In  Calhoun  County,   about  20  feet  of  noncalcareous,   gray, 
platy  shale  is  exposed  along  the  east  bluff  of  the  Mississippi  River,   near  Batchtown. 
In  Kankakee  County,  noncalcareous  beds  are  exposed  along  the  Kankakee  River. 
The  thickness  of  the  Maquoketa  Shale  ranges  from  350  feet,   in  northern  Illinois,   to 
80  feet,   in  the  southern  part  of  the  state  (Weller  and  We  Her,    1939,   p.  7;  Templeton 


4  ILLINOIS    STATE    GEOLOGICAL    SURVEY    CIRCULAR    371 


Figure  1   -  Distribution  of  bedrock  clay  deposits  which  crop  out  in  Illinois 


CLAY    RESOURCES    FOR    LIGHTWEIGHT    CERAMIC    BLOCK  5 

and  Willman,    1963,   p.   131).    The  shale  contains  illite,   chlorite,   and  some  mixed- 
layer  clay  minerals. 

Orchard  Creek  Shale  Member  of  the  Scales  Formation 

The  Orchard  Creek  Shale  is  20  feet  thick  in  Alexander  County,  where  it  crops 
out  along  the  east  valley  wall  of  the  Mississippi  River  between  Thebes  and  Fayette- 
ville.    North  of  Fayette ville,  the  shale  is  green  and  well  laminated.    At  Fayette ville, 
the  shale  is  illitic  and  contains  very  little,   if  any,   lime. 

Mississippian  Shales 

Grassy  Creek  Shale 

The  Grassy  Creek  Shale  is  a  black  fissile  shale  that  weathers  to  a  bluish  or 
greenish  gray.  It  is  50  feet  thick  where  it  crops  out  in  the  Mississippi  River  bluff 
near  Rockport  and  Atlas  in  Pike  County  and  in  the  Illinois  River  bluff  near  Bedford. 
The  shale  thickens  to  the  north  and  east  (Krey,    1924,   p.  34). 

Since  the  fresh  shale  is  fissile  and  contains  organic  matter,  it  is  not  a  good 
bonding  clay;  however,   the  weathered  shale  is  plastic.    The  shale  is  illitic. 

Hannibal  Shale 

The  Hannibal  Shale  ranges  in  thickness  from  about  30  feet,   near  Grafton  in 
Jersey  County,  to  nearly  100  feet,   near  the  north  line  of  Calhoun  County.     In  Pike 
County,  the  Hannibal  Shale  rests  on  the  Grassy  Creek  Shale.    To  the  south,   in  Cal- 
houn and  Jersey  Counties,   the  shale  is  mostly  calcareous  and  nonlaminated,  whereas 
in  the  northern  part  of  Pike  County,  it  may  be  a  massive,   calcareous  sandstone, 
becoming  more  siliceous  to  the  north.    The  shale  has,  for  the  most  part,   a  greenish 
gray  color. 

In  some  areas  of  northern  Calhoun  County,  the  Hannibal  Shale  has  a  low  lime 
and  sand  content,  which  makes  it  suitable  for  a  bonding  clay.    The  areas  of  pro- 
duction would  have  to  be  carefully  selected,   however,  to  assure  the  necessay  low 
calcium  carbonate  and  sand  contents.    The  shale  is  illitic. 

Chesterian  Shale 

The  Chesterian  shales  range  from  calcareous  to  noncalcareous,   and  in  many 
areas,  they  contain  lenses  and/or  beds  of  limestone.    Their  thickness  varies  from 
a  few  feet  to  several  tens  of  feet.    The  Chesterian  shales  range  from  thinly  laminated 
to  massive.    The  colors  may  be  red,  green,   blue-gray,  and  dark  gray. 

The  Chesterian  shales  crop  out  in  Gallatin,   Hardin,   Jackson,  Johnson,   Massac, 
Monroe,   Pope,  Randolph,   and  Union  Counties.    In  some  areas,  these  shales  contain 
too  much  lime  for  use  as  a  bonding  clay.    With  careful  prospecting,   portions  of  the 
Chesterian  shales  that  are  suitable  for  bonding  clay  can  be  found.    The  Chesterian 
shales  are  illitic  for  the  most  part. 

Pennsylvanian  Shales  and  Claystones 

The  Pennsylvanian  shales  and  underclays  are  by  far  the  most  important  bonding 
clay  resources.    These  shales  crop  out  over  a  much  larger  area  of  the  state  than  the 


ILLINOIS    STATE    GEOLOGICAL    SURVEY    CIRCULAR    371 

TstephWsonTwinnTbagoTboone"^  henry  " "Ilake"" 


Figure  2  -  Distribution  of  strippable  refractory  clays  in  Illinois. 


CLAY    RESOURCES    FOR    LIGHTWEIGHT    CERAMIC    BLOCK  7 

older  shales.    Although  most  of  the  thick  Pennsylvanian  shales  are  noncalcareous, 
some  may  contain  limestone  nodules,   lenses,   and/or  beds.    The  underclays  below 
the  Colchester  (No.   2)  Coal  are  usually  noncalcareous,   and  those  above  the  Summum 
(No.  4)  Coal  are  usually  calcareous. 

The  exposed  underclays  in  the  Caseyville,  Abbott,  and  Spoon  Formations  are 
refractory  (i.e.,  they  fuse  above  pyrometric  cone  15).     If  these  underclays  are  used 
with  a  nonrefractory  aggregate,   the  addition  of  a  flux  is  necessary.    The  Abbott  and 
Spoon  Formations,  which  crop  out  in  Adams,   Brown,   McDonough,   Pike,   Schuyler, 
and  Warren  Counties,   also  contain  shales  that  are  refractory.    The  refractoriness 
decreases  from  the  west  edge  of  the  basin,   southeastward  towards  the  center  of  the 
basin.    For  the  most  part,  the  shales  and  underclays  of  the  Carbondale,    Modesto, 
Bond,  and  Mattoon  Formations  are  nonrefractory. 

Cretaceous  Clays  and  Shales 

Clay  materials  of  Cretaceous  age  occur  in  southern  Illinois  in  Alexander, 
Massac,  Pope,  Pulaski,   and  Union  Counties.    These  clays  and  shales  usually  con- 
tain appreciable  percentages  of  kaolinite,  and  are,  therefore,  refractory.    A  flux  is 
required  to  make  them  a  good  bonding  clay.    The  clays  and  shales  vary  in  color  from 
dark  gray  to  light  gray. 

Tertiary  Clay 

Porters  Creek  Clay 

The  Porters  Creek  Clay  is  a  montmorillonite  clay  that  crops  out  in  Pulaski 
County  in  southern  Illinois.     It  is  a  dark  green-gray  clay  that  turns  buff  when  weath- 
ered.   The  Porters  Creek  Clay  is  a  good  bonding  clay  because  of  the  high  montmoril- 
lonite content. 

Pre -Pleistocene  and  Early  Pleistocene  Residual  Clays 

The  residual  clays,   commonly  found  in  western  and  southern  Illinois,   are  usu- 
ally quite  plastic.    The  clays  may  be  white,  red,   or  yellow  in  color.     Some  are  quite 
cherty.    The  thickness  is  variable.    Some  of  the  clays  contain  kaolin     and  are, 
therefore,  refractory.    A  flux  is  needed  to  reduce  the  vitrification  range.     Some  of 
these  clays  contain  montmorillonite  and/or  mixed-layer  clay  minerals  and  no  flux 
would  be  needed. 

Pleistocene  Clay 

Till  might  be  a  suitable  source  of  bonding  clay.    A  till  that  contains  30  per- 
cent clay  and  few  rocks  might  be  considered  a  bonding  clay  resource.    The  Wiscon- 
sinan  till,  which  underlies  the  northeastern  one-third  of  Illinois,   is  usually  calcar- 
eous, except  for  the  upper  few  inches.    The  till  ranges  in  texture  from  clayey  to 
rather  sandy  and  rocky.    To  make  till  a  useful  bonding  clay,  the  calcium  carbonate 
particles  must  be  removed.    The  clay  mineral  in  till  is  chiefly  illite. 

The  Illinoian  till  (fig.  3)  is  noncalcareous  in  the  upper  few  feet  only.     It  could 
be  used  as  a  bonding  clay  if  the  lime  and  material  larger  than  fine  sand  were  removed. 


ILLINOIS    STATE    GEOLOGICAL    SURVEY    CIRCULAR    371 


WmiA 

EXPLANATION  £\        r-S..  ' '  'f   •----'■  .    r 

Thick    loess    deposits,  \\    *--"    "^~S~~1T^Z-  -^>7.:\  v     ; 

greater  than    50  in.  on  till    \X;    if  ""       ^~~"~>-...   .        ^C^~k       ■'■ 

\'         I    Thin    loes   deposes   on   till                '  ^t            L^/L..^     f    \cr  V       \:  ;:i- 
'•-Syv'      ^    ",'\J   tV( ^•-.->-J^..--r 

1     ;|  Alluvial    and   lake    deposits 

|  |  Residual  clays    and  silts    on 

| 1  Thin    lake    clays    and    silts   on    1,11 

, '  Wisconslnan   till   boundary  y  j^ 

Miles  ^     JS?/ 

0        10     20     30     40 

' 1         I 1  I  ^1 

Figure  3  -  Distribution  of  surficial  clay  deposits  in  Illinois. 


CLAY    RESOURCES    FOR    LIGHTWEIGHT    CERAMIC    BLOCK  9 

The  older  Kansan  till  crops  out  in  western  Illinois.    The  till  is  noncalcareous  in  the 
upper  few  feet.     In  areas  west  of  the  Illinois  River,   particularly  near  the  Mississippi 
River,  the  Kansan  and  Illinoian  tills  are  more  montmorillonitic  (Willman,   Glass, 
Frye,    1963,  p.  23)  and  are  probably  the  best  bonding  clays  of  Pleistocene  age. 

CLAY  MATERIALS  INVESTIGATED 

The  following  samples  were  studied. 

Sample  1415  -    NE|  NW{  sec.   13,  T.   6  N.,   R.   5  W.,   about  3  miles  east  of  New 

Douglas,   Bond  County,    south  of  blacktop  road.    The  clay  is  till  5± 
feet  at  top;  shale,   yellow,   plastic  6±  feet;  and  shale,   blue,   plastic 
8  feet  at  bottom.    The  till  is  Illinoian  of  Pleistocene  age  and  the 
shale  is  from  the  Bond  Formation  of  Pennsylvanian  age.    The  clay 
mineralogy  of  the  shale  is  illite  4  parts,   kaolinite  3,   and  chlorite 
3  parts  in  10. 

Sample   866    -    NEi  sec.   11,  T.  33  N.,  R.  8  E.,   7  miles  east  of  Morris,   Grundy 
County.    The  clay  is  3  feet  thick  under  6  feet  of  Pleistocene  over- 
burden.   The  clay  is  Spoon  Formation  of  Pennsylvanian  age.    The 
clay  mineral  components  are  illite  3,   kaolinite  1,   and  mixed-layer 
clay  mineral  6  parts  in  10. 

Sample  2042  -   SW|  SE^  NE*  sec.   15,  T.   12   N.,   R.  9  E.,   east  cut  bank  of  stream 
east  of  road.    About  \  mile  southwest  of  Sparland,   Marshall  County. 
About  3  feet  of  underclay  beneath  Danville  (No.  7)  Coal  in  the  Carbon- 
dale  Formation  of  Pennsylvanian  age.    The  clay  mineral  components 
are  illite  3,   and  mixed-layer  clay  minerals  7  parts  in  10. 

Sample  1422  -  NW  corner  sec.  24,  T.  UN.,  R.  3  E.,  about  1  mile  southwest  of 
Shelbyville,  Shelby  County,  on  east  roadcut  of  north- south  county 
road  in  south  valley  wall  of  creek.  Six  feet  of  shale  is  exposed  in 
roadcut  with  thin  overburden.  The  shale  is  in  the  Bond  or  Mattoon 
Formation  of  Pennsylvanian  age.  The  clay  mineral  components  are 
kaolinite  2,  chlorite  1,  swelling  chlorite  3  to  4,  and  illite  2  parts  in 
10. 

Sample  996N  -  NW^  SW^  WN\  sec.   10,   I.4S..R.5W.,   about  l\  miles  north  of 
Hadley,   Pike  County,   on  north  side  of  old  roadcut  before  road  turned 
north,   in  south  valley  wall  of  Hadley  Creek.    Eight  feet  of  clay  rests 
on  Mississippian  Limestone  and  has  from  10  to  140  feet  of  overburden. 
The  clay  occurs  in  the  Spoon  or  Abbott  Formation  of  Pennsylvanian  age. 
The  clay  mineral  component  is  kaolinite. 

Sample  FE1 13 -NE|  SE|  sec.  27,  T.  15  S.,  R.  IE.,  southeast  of  Olmsted,  Pulaski 
County,  on  the  west  cut  bank  of  Ohio  River.  The  clay,  about  20  feet 
thick  with  20  to  40  feet  of  overburden,  is  in  the  Porter  Creek  Forma- 
tion of  Tertiary  age.  The  clay  mineral  components  are  montmorillon- 
ite  5,   mixed-layer  clay  minerals  3,  and  illite  2  parts  in  10. 


10  ILLINOIS    STATE    GEOLOGICAL    SURVEY    CIRCULAR    371 

Sample  2043  -  Near  center  NE|  sec.  23,   T.   IN.,   R.   12  W. ,   northeast  cut roadbank 
in  southwest  valley  of  Illinois  valley  wall  above  where  road  crosses 
tributary,   Schuyler  County.    The  clay  is  Kansan  till  of  Pleistocene 
age  and  is  5  feet  thick.    The  clay  mineral  components  are  illite  1, 
kaolinite  1,   montmorillonite  4,   and  mixed-layer  clay  minerals  4  parts 
in  10. 


The  mineralogy  of  the  clays  studied  was  determined  by  X-ray  diffraction. 
Samples  composed  of  illite,   montmorillonite,   kaolinite,   chlorite,   and  mixed-layer 
clay  minerals  were  used  in  this  study. 

Procedure 

About  500  pounds  of  clay  were  collected  from  each  location.     Lightweight, 
bloated  shale  aggregate  was  purchased  from  Poston  Brick  and  Concrete  Products 
Company  of  Springfield  and  Western  Brick  Company  of  Danville.    An  8-inch  Raymond 
hammer  mill  was  used  to  grind  the  clay  so  that  it  would  pass  through  a  .010"  x  .47" 
slot  screen.     One  hundred  pounds  of  dry  clay  and  aggregate  were  mixed  in  a  plaster 
mixer  for  4  minutes;  water  was  then  added,   and  mixing  was  resumed  for  another  4 
minutes.    With  clays  that  contained  enough  kaolinite  or  quartz  to  make  them  more 
refractory  than  the  aggregate,   it  was  necessary  to  add  a  flux  to  reduce  the  fusion 
temperature  of  the  clay.    In  only  sample  99 6N,   one  pound  of  fluorspar  was  used  for 
each  20  lbs.  of  clay  and  80  lbs.  of  aggregate  that  were  mixed. 

The  sample  blocks  were  formed  on  either  a  concrete  block  machine  or  a  hy- 
draulic press  with  a  vibrating  mechanism.  The  blocks  were  allowed  to  dry  in  air. 
They  were  then  placed  in  an  electric  kiln  and  fired  to  1850°  -1900°  F.  (1010  to  1038° 
C.)  for  24-hours.    After  firing,  the  blocks  were  capped.    A  Riehle  compression  mach- 
ine (300,  000  lbs.  maximum  capacity)  was  used  to  test  for  compressive  strength. 
The  maximum  capacity  was  applied  to  the  blocks  for  2  minutes.    The  results  are  given 
in  table  1. 

Fragments  of  the  crushed  tile  were  placed  in  cold  water  for  24  hours.    The 
samples  were  then  weighed  and  placed  in  an  oven  at  110°  C,   overnight.    The  sam- 
ples were  weighed  again  to  determine  the  porosity. 

Test  Results 

Forming  Properties 

The  strongest  blocks  were  made  from  mixtures  in  which  20  percent  clay  and 
80  percent  aggregate  (l/l 6"-0)  were  mixed  dry  and  about  16  percent  water  added  and 
mixed.    FE113  was  an  exception,  however.     Good  blocks  were  obtained  with  only 
10  percent  clay  (FE113).    To  use  a  larger  percentage  of  clay,   more  water  would  be 
necessary.    An  excess  of  water,  however,  caused  the  mix  to  stick  to  the  machine; 
an  insufficiency  of  water  caused  the  blocks  to  be  crumbly  when  air  dried.     When  less 


CLAY   RESOURCES    FOR    LIGHTWEIGHT    CERAMIC    BLOCK 


than  16  percent  of  water  was  used,   a  reduction  in  block  strength  resulted.    This 
suggests  that  there  was  not  enough  water  to  allow  the  bonding  mechanism  of  the 
clay  to  develop  fully.    This  bonding  mechanism  is  probably  due  to  the  development 
of  a  wedge-shaped  mass  of  clay  at  the  junctions  of  the  aggregate  grains  (Grim  and 
Cuthbert,    1946,   p.   15)  and  the  formation  of  a  glassy  phase,  which  bonds  the  vitri- 
fied clay  wedge  and  the  aggregate  together.    The  clay  must  be  lubricated  with  water 
so  that  it  can  coat  the  particles  of  aggregate  to  give  the  best  bond  structure  when 
the  blocks  are  fired. 

Drying  Properties 

The  sample  blocks  were  dried  in  air;  however,  the  open-pore  structure  of  the 
blocks  would  allow  them  to  be  dried  without  difficulty  at  a  more  rapid  rate.     Bell  and 
McGinnis  (1951,   p.   338)  state  that  no  difficulty  was  encountered  in  drying  blocks 
at  above  212°  F. 

Firing  Properties 

The  samples  were  fired  for  24  hours  at  1850-1900°  F.     Bell  and  McGinnis 
(1951,   p.  338)  used  a  l\  hour  schedule,  whereas  Caruso  (1959,   p.  80)  used  a  tunnel 
kiln  with  a  5  hour  and  40  minute  firing  schedule. 

The  total  shrinkage  in  this  study  ranged  from  5  to  13  percent  (table  1). 

Block  can  be  flashed  in  the  same  manner  as  brick.     One  group  of  blocks  was 
fired  in  an  atmosphere  of  insufficient  oxygen;  these  samples  did  not  bloat.    The  color 
of  the  blocks  in  this  group  was  much  lighter,   and  some  of  the  blocks  were  pink 
instead  of  the  red  produced  in  a  completely  oxidizing  atmosphere.    The  strength  of 
these  blocks  was  similar  to  the  strength  of  those  burned  in  an  oxidizing  atmosphere. 

Other  Properties 

The  sample  blocks  (figs.  4  and  5)  had  a  pleasing  appearance.    The  colors 
were  similar  to  those  found  in  brick.     Color  can  be  changed  by  additives,   flashing 
in  kiln,   or  varying  the  temperature  of  the  kiln.     Blocks  can  be  glazed  to  obtain 
colors  that  cannot  be  produced  by  the  above  processes. 

Ceramic  blocks  show  a  thermal  expansion  more  nearly  equal  to  that  of  brick 
than  do  concrete  blocks.    Texture  can  be  changed  by  increasing  or  reducing  the  per- 
centage of  the  fines  and  by  using  a  larger  aggregate  size.    The  clay  block  will  not 
shrink . 

If  a  white  burned  product  is  desired,  the  white  burning  clay  should  be  used 
as  a  glaze  or  terra  sigillatta  on  the  surface  of  the  block.    When  a  white  burning  clay 
is  used  as  a  bonding  clay,  it  only  lightens  the  burning  color  of  the  aggregate. 

Clays  containing  montmorillonite  may  require  less  clay  to  give  the  desired 
strength  (sample  FE113)  or  more  nonclay  material  can  be  tolerated  (sample  2043). 

All  seven  clays  tested  produced  blocks  that  had  a  strength  of  over  1,000 
pounds  per  square  inch.     Five  of  the  clays  had  an  average  strength  of  over  1,  400 
pounds.    The  average  strength  of  blocks  from  one  clay  (sample  1415)  was  over  1,700 
pounds  per  square  inch,  and  some  of  these  blocks  had  a  strength  of  1900  psi. 

Blocks  fired  to  1850°  F.  were  soft  enough  that  nails  driven  into  them  did  not 
bend  (fig.  5),   and  they  could  be  sawed  with  a  handsaw. 


ILLINOIS    STATE    GEOLOGICAL    SURVEY    CIRCULAR    371 


TABLE  1  -  POROSITY  AND  STRENGTH  OF  CLAY  AND  AGGREGATE  MIXES 


Mixture  Percent 

H20 
Percent 

After  Firing 

Sample 

PSI 

Percent 
Porosity 

No. 

Clay   1  Aggregate 

Remarks 

15.0 

603 



20.0 

1406 

25.2 

10.0 

— 

— 

20.0 

356 

— 

10.0 

— 

— 

10.6 

262 

— 

20.0 

1442 

26.2 

Too  wet 

15.0 

1124 

22.0 

15.0 

635 

— 

20.0 

1880 

22.6 

9.0 

374 

— 

Too  dry 

20.0 

1304 

__ 

10.0 

740 

— 

Coarser  Aggregat 

10.0 

360 

32.0 

Finer  Aggregate 

20.0 

— 

32.0 

15.0 

1439 

28.0 

10.0 

509 

— 

9.0 

300 



10.0 

278 

— 

5.0 

— 

— 

Too  dry 

15.0 

1714 

13.5 

15.0 

1292 

19.0 

10.0 

<252 

31.5 

Too  dry 

11.0 

596 

— 

Too  dry 

15.0 

774 

25.5 

15.0 

1109 

17.3 

10.0 

<400 

28.0 

12.3 

850 

— 

5.0 

184 

__ 

Too  dry 

15.0 

1092 

29.0 

20.0 

— 

— 

Too  wet 

10.0 

275 

— 

15.0 

1033 

— 

10.0 

979 

25.6 

20.0 

780 

— 

15.0 

760 

— 

10.0 

430 

— 

10.3 

603 

— 

10.0 

480 

__ 

15.0 

1472 

30.0 

10.0 

900 

25.5 

15.0 

967 

— 

11.0 

313 

— 

CLAY   RESOURCES    FOR    LIGHTWEIGHT    CERAMIC    BLOCK  13 


Figure  4  -  Lightweight  block  made  from  various  Illino: 


ILLINOIS    STATE    GEOLOGICAL    SURVEY    CIRCULAR    371 

CONCLUSIONS 

Many  of  the  deposits  of  clay  and  shale  in  Illinois  could  be  used  in  the  manufac- 
ture of  lightweight  ceramic  blocks  . 

Either  the  brick  industry  or  the  concrete  block  industry  could  produce  ceramic 
blocks  as  a  second  product  with  a  minimum  of  additional  equipment.     Brick 
manufacturers   already  have  the  processing  machinery  for  preparing  the  clay 
and  the   kiln  for  firing  the  finished  product,   whereas  a  plant  that  manufactures 
concrete  block  would  have  the  mixing  equipment  and  the  shaping  machinery. 

The  blocks  make  excellent  building  materials  because  they  are  strong  and 
aesthetically  pleasing. 

Clay  block  can  be  used  in  most  places  where  concrete  block  can  be  used. 

Clay  blocks  will  not  shrink. 

A  curing  period  is  not  required. 

Clay  blocks  would  be  more  compatible  with  the  thermal  and  permanent  expansion 
of  brick  than  would  concrete  blocks. 

Generally,  clay  material  with  abundant  montmorillonite  and  mixed-layer  clay 
minerals  are  good  bonding  clays.     If  clays  containing  montmorillonite  are  used, 
less  clay  may  be  required  to  give  the  desired  strength  (sample  FE113).    Clay 
materials  that  contain  abundant  nonclay  material  (sample  2043)  may  require  a 
higher  ratio  of  clay  to  aggregate  than  clays  with  less  nonclay  components. 


Bell,  W.  C,  and  McGinnis,  D.  H.,  1951,  The  development  of  large  lightweight 
structural  clay  building  units.  II.  Lightweight  clay-aggregate  building  units: 
Am.  Ceramic  Soc.  Bull.,   v.  30,   no.   12,   p.  336-339. 

Caruso,   P.  A.,    1959,   New  design  data  for  clay  bonded  block:    Brick  and  Clay  Rec, 
v.   135,   no.  4,   p.   69-87. 

Grim,  R.  E.,  and  Cuthbert,  F.  L.,  1946,  The  bonding  action  of  clays.  Part  II  - 
Clays  in  dry  molding  sands:    Illinois  Geol.  Survey  Rept.  Inv.   110,   36  p. 

Krey,  Frank,  1924,  Structural  reconnaissance  of  the  Mississippi  Valley  area  from 
Old  Monroe,   Missouri,  to  Nauvoo,  Illinois:    Illinois  Geol.  Survey  Bull.  45,   86  p. 

Moffitt,  R.  B.3  1961,  Determine  firing  schedule  of  ceramic  block:  BrickandClay 
Rec,  v.   139,   no.  5,   p.   60-83. 

Robinson,   G.  C,    1961,   Clay  block  on  concrete  block  machine:    Brick  and  Clay  Rec. 
v.   139,   no.   5,    p.   43-47. 

Robinson,  G.  C,  1962,  Clay  block  on  concrete  block  machines:  Brick  and  Clay 
Rec,   v.   140,   no.   1,   p.   66-87. 

Rubey,  W.  W. ,    1952,   Geology  and  mineral  resources  of  Hardin  and  Brussels  Quad- 
rangles (in  Illinois):    U.  S.  Geol.  Survey  Prof.  Paper  218,    179  p. 


CLAY    RESOURCES    FOR    LIGHTWEIGHT    CERAMIC    BLOCK  15 

Templeton,   J.  S.,   and  Willman,   H.  W.,    1963,   Champlainian  Series  (Middle  Ordo- 
vician)  in  Illinois:    Illinois  Geol.  Survey  Bull.  89,    260  p. 

Weller,   Stuart,   and  Weller,   J.  M.,    1939,   Preliminary  geological  maps  of  the  pre- 
Pennsylvanian  Formations  in  part  of  southern  Illinois  -  Waterloo,  Kimmswick, 
New  Athens,  Crystal  City,   Renault,   Baldwin,  Chester,   and  Campbell  Hill  Quad- 
rangles:   Illinois  Geol.  Survey  Rept.  Inv.   59,    15  p. 

Willman,  H.  B.,   Glass,   H.  D.,   and  Frye,   J.  C,    1963,   Mineralogy  of  glacial  tills 
and  their  weathering  profiles  in  Illinois.     Part  I  -  Glacial  tills:    Illinois     Geol. 
Survey  Circ.  347,    55  p. 


Illinois  State  Geological  Survey  Circular  371 
15  p.,    5  figs.,    1  table,    19  64 


Printed  by  Authority  of  State  of  Illinois,   Ch .    127,   IRS,    Par.   58.25. 


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