Prevention and solution strategies for common quality problems of bricks

Prevention and solution strategies for common quality problems of bricks

Quality problems with bricks not only affect sales, but also expose loopholes in the production process. An effective strategy should be "prevention first, solution second", and ensure results by controlling the process. Here are systematic strategies for common problems.

1. Cracking (cracks, fractures)

Prevention strategies:

Raw material control: Ensure the reasonable gradation of raw materials and ensure that they contain a certain proportion of fine particles (such as an appropriate amount of clay) to enhance plasticity. Stirring must be thorough and even.

Pre-curing after forming: The newly pressed wet bricks must be immediately moved to a wind-proof, sun-shaded, and humid curing area to rest (at least 12-24 hours) to allow moisture to spread evenly, which is the key to preventing drying and cracking.

Smooth operation: Optimize the demoulding and handling process to avoid bumps or internal injuries to the low-strength wet blanks.

Solution:

If cracking has occurred, immediately check and adjust the raw material ratio (add plastic material).

Check whether the temperature and humidity control in the conservation area meets the standards and strengthen moisturizing measures.

Check the stability of the demoulding mechanism.

2. Insufficient strength and fragile

Prevention strategies:

Strictly control the ratio and raw materials: Use proven and accurate raw material ratios, especially cement and other cementitious materials that must be measured accurately. The raw materials need to be clean and have low impurity content.

Ensure the molding density: Ensure that the molding pressure of the brick making machine is stable and sufficient, which is the basis for the bricks to obtain high density.

Standardize the maintenance system: Develop and strictly implement maintenance procedures to ensure that the bricks receive sufficient watering, moisturizing and appropriate temperature during the critical period of strength development (especially the first 3-7 days).

Solution:

Immediately recalibrate the batching scale and check whether materials such as cement are expired or affected by moisture.

Test and calibrate the pressure system of the brick making machine to ensure that the pressure value reaches the standard.

Strengthen maintenance management and perform remedial maintenance on already produced batches.

3. Missing corners, missing edges, and inaccurate dimensions

Prevention strategies:

Mold management: Establish mold files, regularly inspect, repair or replace worn and deformed molds. Clean the mold every shift to prevent material from sticking.

Uniform distribution: Adjust the feeding device to ensure that the raw materials can evenly and fully fill every corner of the mold.

Ensure smooth demoulding: Check and optimize the demoulding mechanism to ensure uniform force during demoulding and avoid forced demoulding.

Solution:

Stop production immediately and replace the problem mold.

Check and adjust the fabric system.

Sorting of defective bricks produced.

4. Uneven appearance color and loose surface

Prevention strategies:

Stir fully: Ensure sufficient mixing time and correct mixing method to mix the raw materials evenly.

Raw material screening: Screen the raw materials to remove impurities.

Ensure molding pressure: Ensure the pressure is sufficient to make the surface of the brick dense.

Solution:

Check whether the mixer is working properly and extend the mixing time.

Strengthen raw material entry inspection.

5. Systematic quality control strategy

Establish critical control points (CCP): Set up checkpoints in the three core links of batching, molding and maintenance, formulate clear standards and record them.

Implement traceability management: record the raw material batch, production time, and main process parameters (pressure, maintenance records) for each batch of bricks. Once a problem occurs, the cause can be traced quickly and accurately.

Regular inspection and data feedback: Regularly send finished brick samples to authoritative institutions to test strength, durability and other indicators, use data to verify whether the production process is under control, and guide improvements.

Summary: eliminate problems in the process

The most efficient way to solve brick quality problems is to prevent them from happening. This requires managers to move their quality awareness from "final inspection" to "whole process control". Through the four pillars of stable raw materials, accurate proportions, guaranteed pressure, and standardized maintenance, supplemented by a data recording and traceability system, most quality problems can be systematically prevented and stable, high-quality production can be achieved.