From old-world to contemporary craft: Inside the modern brick-making process with PGH Bricks

Bricks have been used as a construction material for almost as long as humans have been building structures, for good reason.

“Bricks are a reliable and versatile building material, known for their strength and ability to withstand harsh weather, fire, and everyday wear,” says Nic Berthoud of PGH Bricks.

“They offer excellent thermal efficiency, helping to keep homes comfortable year-round while reducing energy costs. Low-maintenance and naturally resistant to pests and decay, bricks are also a tried-and-true option that never goes out of style.”

Considering the first known fired bricks are dated circa 4000 BC, with air-dried bricks even older, it’s certainly true that bricks are timeless. Though some of those early brick structures still exist today, the brick-making process has developed significantly, with technology and ingredient developments lending to the increased efficiency, consistency, and durability of today’s brick industry. ArchiPro caught up with Nic Berthoud of PGH Bricks to learn more about modern brick-making.

“Bricks offer excellent thermal efficiency, helping to keep homes comfortable year-round while reducing energy costs. Low-maintenance and naturally resistant to pests and decay, bricks are also a tried-and-true option that never goes out of style.”

Achieving consistency with technology

“Historically, bricks were shaped manually using wooden moulds and fired in simple kilns,” Nic explains.

“Today, modern brick plants use advanced machinery, robotics, and computer-controlled tunnel kilns to ensure consistency, quality, and efficiency. PGH also incorporates recycled materials in the manufacturing process, which reduces energy consumption, and employs more eco-friendly firing techniques.”

This process allows the manufacturer to control the size, shape, texture, and colour of the bricks, guaranteeing a consistent and uniform product.

“Texture is influenced by the type of clay and manufacturing processes, from smooth pressed finishes to rougher, sand-faced surfaces. PGH manages these elements and uses firing techniques to produce bricks that are not only structurally reliable but also suited to a wide range of applications, from load-bearing walls to decorative facades.”

Creating variety in colour and texture

Brick colour is determined by natural minerals in the clay and the firing process.

“Key components include iron oxide (for brown, red and orange bricks), lime and calcium carbonate (for creams and white tones), manganese dioxide (for deep browns) and additives and surface treatments (to apply a finished colour to the brick),” Nic says.

“Firing temperatures and atmosphere also contribute to oxygen levels that impact the overall colour of the brick.”

Alongside colour, the composition of the clay, sand, and any additives play a crucial role in developing a brick’s properties. For example, a higher silica content will enhance strength, while controlling levels of lime will prevent weaknesses.

“Texture is influenced by the type of clay and manufacturing processes, from smooth pressed finishes to rougher, sand-faced surfaces. PGH manages these elements and uses firing techniques to produce bricks that are not only structurally reliable but also suited to a wide range of applications, from load-bearing walls to decorative facades.”

PGH Bricks’ tried and true selection of colours, textures and finishes have been chosen to suit both contemporary and traditional architectural styles.

“Our advanced manufacturing techniques allow us to produce high-quality, durable bricks. We are also proud to say we implement eco-friendly practices such as energy-efficient kilns and use recycled materials. Our range has recently extended with two new colours: Driftwood Grey (a grey brick) and Eclipse (a black brick). Watch this space for new additions!”

Australian-made bricks for the New Zealand market

Formerly known as Monier Bricks, PGH Bricks recently rebranded.

“PGH Bricks & Pavers are part of the CSR family and are proudly manufactured in Australia. Our name has changed, but our commitment to providing quality bricks will not as we continue to supply the trusted, timeless bricks that have helped (quite literally) shape New Zealand homes for generations. Watch this space for more exciting developments to our range!”

PGH Bricks operates multiple manufacturing plants across Australia, ensuring a reliable supply of Australian-made bricks for the New Zealand market.

Learn more about PGH Bricks.