Analysis of brick production process: quality control from raw materials to finished products

Analysis of brick production process: quality control from raw materials to finished products

Producing a qualified brick is an interlocking systematic project. Quality control is not just about final inspection, but runs through every step from raw materials to finished products. To ensure stable quality, we must firmly grasp the control points of the following four core links.

1. Raw material and ratio control: laying the “gene” for strength

This is the basis for determining the intrinsic quality of bricks, and source control is crucial.

Control points:

Stable raw materials: The specifications and sources of cement and aggregates (sand, stone powder, cinder, etc.) should be relatively fixed. The raw materials entering the factory need to be briefly inspected to avoid the use of damp and agglomerated cement or sand with excessive mud content.

Accurate proportioning: weigh or measure strictly according to the successful formula. Cement is the "glue" of strength and must be used in sufficient and accurate amounts. The particle size of aggregates should be matched appropriately.

Moderate moisture: The amount of water added is the core process parameter. If there is too much moisture, the bricks will be soft, easy to deform, and easy to crack later; if there is too little moisture, the materials will be dry and scattered, and the bricks will not be compacted. The goal is for the mixture to "form into a ball when you hold it in your hand and spread out when you hit the floor."

Stir thoroughly: Make sure that all materials, especially cement and water, are mixed evenly in the mixer without dry lumps or uneven color.

2. Forming and suppression control: shaping a dense “body”

The forming process gives the brick its shape and initial density, which directly affects the strength of the finished product.

Control points:

Uniform filling: The amount of mixture filled into the mold each time must be stable, sufficient and evenly distributed. If there is less material, the bricks will not be full, and if there is too much material, the pressure will be abnormal.

Pressure and time guarantee: Ensure that the molding pressure (or vibration force) provided by the equipment is sufficient and maintain sufficient pressurization/vibration time. If the pressure is insufficient or the time is too short, the interior of the bricks will be loose, which is the direct cause of poor strength.

The mold is in good condition: the mold must be clean, not deformed, and installed accurately. Worn or dirty molds can lead to inaccurate brick dimensions, rough surfaces, and missing edges and corners.

3. Maintenance management and control: achieving strength “growth”

This is the most easily overlooked but most critical link, where the ultimate strength of the brick is "developed".

Control points:

Initial resting: The formed wet bricks need to rest on the pallet for a sufficient period of time (usually more than 12-24 hours), and then move after they have gained initial strength to prevent deformation.

Moisturizing and curing (core): After resting, the bricks must be moved to a sun-shaded and wind-sheltered curing area, and the environment must be kept moist (such as covering with plastic sheeting and spraying water). This stage takes at least 5-7 days to ensure sufficient hydration of the cement. It is strictly prohibited to expose it to the sun or strong wind, otherwise it will cause surface cracking and serious lack of internal strength.

Standard stacking: When stacking in the later stage of maintenance, they should be neat and stable, and continue to avoid rain and exposure.

4. Process Inspection and Records: Establish traceable “files”

Systematic inspection and recording are the basis for identifying problems and making continuous improvements.

Control points:

Process sampling inspection: Wet bricks are randomly selected at regular intervals to check size, weight and appearance uniformity. Conduct simple strength tests (such as beating, load-bearing) on the cured finished products.

Keep sample for comparison: fix a successful formula and process as a "standard sample", and perform comparative analysis when the quality fluctuates.

Key parameter recording: simply record daily raw material batches, water addition volume, weather, maintenance measures, etc. Once a problem occurs, these records are the most valuable clues to trace the cause.

In summary, the quality control of brick making is a complete closed loop: stable raw materials and precise proportions are the prerequisite, sufficient molding and density are the foundation, and scientific and patient maintenance is the soul that determines the final strength. By grasping the three cores of "accurate proportions, sufficient pressure, and good maintenance" and supplemented by process inspections, you can systematically ensure that each batch of bricks is strong, regular, and durable, thereby establishing a reliable market reputation.