Clay taken from a quarry or river is mixed with other raw materials such as sand, lava, lime, iron and chromium oxides. The clay is put through various processes to remove any unwanted aggregates or metals. It is then kneaded with steam and water before being thrown by machine into a “Deboer” press. The moulds are lined with a fine or course sand lubricant depending on the desired end texture, and then dried. The shaped bricks are fired in a tunnel kiln at temperatures ranging from 1070-1250°c. The resulting base brick is cooled and then fully immersed in a liquid clay bath with cement pigment added to achieve the desired colour. It is then naturally dried producing a durable and frost resistant facing layer.

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