Basic Steps in the Brick Manufacturing Process

Basic Steps in the Brick Manufacturing Process

Producing a qualified brick is not simply a matter of pressing, but rather a series of interconnected standard processes. Understanding and mastering the following five basic steps is fundamental to ensuring production volume, quality, and cost control.

I. Raw Material Preparation and Mixing: Laying the Foundation

This is the primary step that determines the final strength and cost of the bricks.

Raw Material Proportioning: According to the formula, cement and aggregates (such as sand, stone powder, coal slag, etc.) are weighed or measured in precise proportions. Cement is the "glue," and its quantity and quality are crucial; the particle size distribution (gradation) of the aggregates affects the density.

Water Addition and Mixing: The prepared dry materials are fed into a mixer, and an appropriate amount of water is added for thorough and uniform mixing. Water content control is key: too little water results in a dry, loose mixture that is difficult to compact; too much water results in a soft brick blank that is easily deformed, and prone to cracking due to large shrinkage during drying. The goal is a mixture that "forms a ball when squeezed by hand, but crumbles when dropped."

II. Forming and Pressing: Giving Shape and Initial Strength

This is the core process of shaping the loose mixture into brick blanks using mechanical force.

Filling: The mixed material is evenly and appropriately filled into the machine's mold. The filling amount must be accurate; too much or too little will directly affect the size and density of the brick blank.

Pressing/Vibration Forming: The machine uses high-pressure compaction and/or high-frequency vibration to tightly compress the mixture in the mold, expelling air and forming a regular brick blank with a certain initial strength. The magnitude and duration of the pressure (or vibration force) directly affect the density of the brick blank.

Demolding: After forming, the brick blank is pushed or ejected from the mold and transferred to a curing tray (pallet). This process must be smooth to avoid damaging the wet, soft brick blank.

III. Brick Blank Curing: Achieving Final Strength

This is the most easily overlooked but crucial step; the brick's strength "grows" here.

Static Pre-curing (Initial Curing): The newly demolded wet brick blanks need to be left to stand on the tray for a period of time (usually 12-24 hours) to gain initial strength, facilitating subsequent handling. Moisture Curing (Critical Stage): Transfer the brick blanks to a curing area (such as a shaded shed) and maintain a humid environment by covering them with plastic sheeting and regularly spraying them with water mist. This stage should last for several days to a week to ensure that the cement fully completes the hydration reaction in a moist environment, thereby achieving the designed strength. Avoid direct sunlight or strong winds that can cause rapid moisture loss; otherwise, the bricks may crack or lack sufficient strength.

Natural Drying: After moisture curing is complete, remove the covering and allow the brick blanks to continue drying under natural conditions until the moisture content meets the requirements.

IV. Finished Product Stacking and Storage

Only after curing is complete can the bricks be neatly stacked.

The stacking area should be flat and firm.

The stacks should be neat and stable, with ventilation gaps to facilitate continued drying and loading/unloading.

V. Quality Control and Auxiliary Processes

Ensuring quality throughout the entire process.

Process Control: Inspections should be conducted at every stage, such as checking the dryness and humidity of raw materials, the appearance and dimensions of the brick blanks, and the temperature and humidity of the curing environment.

Equipment and Mold Maintenance: Regularly clean and maintain the brick-making machine and mixer, especially cleaning the molds, to ensure accurate molding every time.

In summary, brick production is a systematic engineering process involving "proportioning, mixing, pressing, curing, and storage." It requires: precise raw material proportioning as the foundation, thorough mixing and standardized pressing as the core, and scientific and patient curing as the soul that guarantees the final strength and durability of the bricks. Neglecting any one of these steps can lead to defects in the finished product. By mastering this process, you can systematically improve brick quality and production efficiency.