Clay

Clays develop plasticity when wet but can be hardened through firing. Clay is the longest-known ceramic raw material. Prehistoric humans discovered the useful properties of clay and used it for making pottery. Some of the earliest pottery shards have been dated to around 14,000 BCE, and clay tablets were the first known writing medium. Clay is used in many modern industrial processes, such as paper making, cement production, and chemical filtering. Between one-half and two-thirds of the world's population live or work in buildings made with clay, often baked into brick, as an essential part of its load-bearing structure. In agriculture, clay content is a major factor in determining land arability. Clay soils are generally less suitable for crops due to poor natural drainage; however, clay soils are more fertile, due to higher cation-exchange capacity.

Clay is a very common substance. Shale, formed largely from clay, is the most common sedimentary rock. Although many naturally occurring deposits include both silts and clay, clays are distinguished from other fine-grained soils by differences in size and mineralogy. Silts, which are fine-grained soils that do not include clay minerals, tend to have larger particle sizes than clays. Mixtures of sand, silt and less than 40% clay are called loam. Soils high in swelling clays (expansive clay), which are clay minerals that readily expand in volume when they absorb water, are a major challenge in civil engineering.

Properties

The defining mechanical property of clay is its plasticity when wet and its ability to harden when dried or fired. Clays show a broad range of water content within which they are highly plastic, from a minimum water content (called the plastic limit) where the clay is just moist enough to mould, to a maximum water content (called the liquid limit) where the moulded clay is just dry enough to hold its shape. The plastic limit of kaolinite clay ranges from about 36% to 40% and its liquid limit ranges from about 58% to 72%. High-quality clay is also tough, as measured by the amount of mechanical work required to roll a sample of clay flat. Its toughness reflects a high degree of internal cohesion.

Clay has a high content of clay minerals that give it its plasticity. Clay minerals are hydrous aluminium phyllosilicate minerals, composed of aluminium and silicon ions bonded into tiny, thin plates by interconnecting oxygen and hydroxide ions. These plates are tough but flexible, and in moist clay, they adhere to each other. The resulting aggregates give clay the cohesion that makes it plastic. In kaolinite clay, the bonding between plates is provided by a film of water molecules that hydrogen bond the plates together. The bonds are weak enough to allow the plates to slip past each other when the clay is being moulded, but strong enough to hold the plates in place and allow the moulded clay to retain its shape after it is moulded. When the clay is dried, most of the water molecules are removed, and the plates form direct hydrogen bonds with each other, making the dried clay rigid but still fragile. If the clay is moistened again, it will once more become plastic. When the clay is fired to the earthenware stage, a dehydration reaction removes additional water from the clay, causing clay plates to irreversibly adhere to each other via stronger covalent bonding, which strengthens the material. The clay mineral kaolinite is transformed into a non-clay material, metakaolin, which remains rigid and hard if moistened again. Further firing through the stoneware and porcelain stages further recrystallizes the metakaolin into yet stronger minerals such as mullite.

The tiny size and plate form of clay particles gives clay minerals a high surface area. In some clay minerals, the plates carry a negative electrical charge that is balanced by a surrounding layer of positive ions (cations), such as sodium, potassium, or calcium. If the clay is mixed with a solution containing other cations, these can swap places with the cations in the layer around the clay particles, which gives clays a high capacity for ion exchange. The chemistry of clay minerals, including their capacity to retain nutrient cations such as potassium and ammonium, is important to soil fertility.

Clay is a common component of sedimentary rock. Shale is formed largely from clay and is the most common of sedimentary rocks. However, most clay deposits are impure. Many naturally occurring deposits include both silts and clay. Clays are distinguished from other fine-grained soils by differences in size and mineralogy. Silts, which are fine-grained soils that do not include clay minerals, tend to have larger particle sizes than clays. There is, however, some overlap in particle size and other physical properties. The distinction between silt and clay varies by discipline. Geologists and soil scientists usually consider the separation to occur at a particle size of 2 μm (clays being finer than silts), sedimentologists often use 4–5 μm, and colloid chemists use 1 μm. Clay-size particles and clay minerals are not the same, despite a degree of overlap in their respective definitions. Geotechnical engineers distinguish between silts and clays based on the plasticity properties of the soil, as measured by the soils' Atterberg limits. ISO 14688 grades clay particles as being smaller than 2 μm and silt particles as being larger. Mixtures of sand, silt and less than 40% clay are called loam.

Some clay minerals (such as smectite) are described as swelling clay minerals, because they have a great capacity to take up water, and they increase greatly in volume when they do so. When dried, they shrink back to their original volume. This produces distinctive textures, such as mudcracks or "popcorn" texture, in clay deposits. Soils containing swelling clay minerals (such as bentonite) pose a considerable challenge for civil engineering, because swelling clay can break foundations of buildings and ruin road beds.

Agriculture

Clay is generally considered undesirable for agriculture, although some amount of clay is a necessary component of good soil. Compared to other soils, clay soils are less suitable for crops due to their tendency to retain water, and require artificial drainage and tillage to make suitable for planting. However, clay soils are often more fertile and can hold onto nutrients better due to their higher cation-exchange capacity, allowing more land to remain in production rather than being left fallow. As clay tends to retain nutrients for longer before leaching them, this also means plants may require more fertilizer in clay soils.