Key points of quality control in brick production process

Key points of quality control in brick production process

The key to stably producing qualified bricks lies in systematic quality control of the entire production process. Embedding quality control points into every key link is the fundamental method to ensure product consistency and reduce costs and scrap rates.

1. Raw material processing and ingredients: source control

This is the first barrier to quality and determines the inherent potential of the bricks.

Raw material entry inspection: Establish simple raw material acceptance standards, conduct visual inspection and feel inspection of each batch of sand, gravel, fly ash and other main materials to ensure that their cleanliness, moisture content and particle gradation are basically stable, and remove large impurities and excessive soil.

Precision and stability of ingredients: this is the core of quality control. Calibrated weighing tools must be used, and batching must be carried out in strict accordance with the optimized proportions verified by experiments, especially the proportions of cement and other cementitious materials, which are never allowed to be estimated based on experience. Any fluctuation in the proportion will directly lead to unstable strength of the finished product.

Uniformity of mixing: Ensure that the mixing time is sufficient so that water, cementitious materials and aggregates are fully mixed and evenly mixed, and the dry humidity is consistent. Uneven mixing will lead to uneven internal strength of the bricks and easy cracking.

2. Forming process: giving shape and initial strength

The forming process determines the density, dimensional accuracy and appearance of the bricks.

Monitoring of forming pressure: The forming pressure of the brick making machine must be stable within the set range. If the pressure is insufficient, the bricks will not be dense and have poor strength; if the pressure is too high or fluctuates, cracks or dimensional deviations may occur. Pressure systems need to be checked, documented and calibrated regularly.

Standardized management of molds: The mold is the "master" of the bricks, and its status directly affects the appearance of the product. It is necessary to regularly check the wear and deformation of the mold and repair or replace it in time. The mold must be cleaned before and after each shift of production to ensure smooth demoulding and prevent the sticky material from straining the bricks.

Cloth uniformity control: Ensure that the filling of raw materials into the mold is uniform and sufficient to avoid local shortages or uneven density. This is the key to preventing missing corners, edges and uneven strength of bricks.

3. Maintenance link: guarantee of strength development

After the bricks are formed, curing is a chemical reaction process that determines their final strength and is very important.

Resting (pre-curing) management: The newly formed wet bricks must rest for a sufficient period of time (usually 12-24 hours) in a wind-proof, sun-shaded, and humid environment to make the internal moisture uniform and initially hardened. This is a key step to prevent cracking.

Institutionalization of sprinkling maintenance: According to the climate and season, clear sprinkling maintenance procedures (such as starting time, frequency, water volume) are formulated and strictly implemented. Ensure that the bricks maintain appropriate humidity during the critical period of strength development (especially the first 3-7 days). Insufficient maintenance is a common cause of substandard strength.

Maintenance environment control: Plan a dedicated maintenance area with flat ground and sun and rain protection conditions. Different batches of bricks should be clearly stacked in separate areas to facilitate management and recording of maintenance cycles.

4. Inspection and traceability: closed-loop management and continuous improvement

Quality control must form a closed loop and rely on data-driven decision-making.

Set process inspection points: Set up inspection points after batching, after molding, and in the middle of maintenance. For example, spot check the appearance size and integrity of wet blanks, and quickly detect the temperature and humidity in the curing area.

Regular inspection of finished products: According to national standards or customer requirements, finished brick samples are regularly sent to professional institutions for testing of key indicators such as compressive strength and water absorption, and authoritative data is used to verify whether the production process is continuously under control.

Establish a traceability system: Establish a simple file for each batch of products to record the batch of raw materials used, production date, key process parameters (such as pressure value), maintenance records and final inspection results. Once a quality problem occurs, it can be quickly and accurately traced to the problem link to achieve targeted improvements.

Summary: Standard work, data speaks for itself, and everyone participates

Quality control is not a matter for the quality inspector alone, but a systematic project that requires the participation of all employees. Managers should clarify the quality standards and operating specifications for each link, and ensure their implementation through training and supervision. The core is to transform production that relies on personal "experience" into a controllable process driven by clear standards, stable parameters and objective data. When the four core points of "raw material ratio, molding pressure, maintenance management, and inspection and traceability" are effectively controlled, the stable output of high-quality bricks will be a natural result.