Quality Control Key Points in the Brick Manufacturing Process

Quality Control Key Points in the Brick Manufacturing Process

Producing qualified bricks consistently hinges on systematic quality control throughout the entire production process. Integrating control points into each critical stage is the fundamental method for ensuring product consistency and reducing the scrap rate.

I. Raw Materials and Batching Stage: The First Line of Quality Control

This is the foundation of quality; loss of control at the source makes subsequent adjustments difficult.

Raw material incoming inspection: Conduct simple inspections of each batch of sand, gravel, fly ash, and other main materials to ensure they are free of excessive impurities and soil, and that the particle size distribution is basically stable.

Accuracy and stability of batching: This is a core control point. Calibrated weighing tools must be used, and batching must strictly follow the optimized proportions verified through testing, especially the proportion of cement and other cementing materials.  Estimation based on experience is absolutely not allowed. Any fluctuation in the proportion will directly lead to unstable finished product strength.

Uniformity of mixing: Ensure sufficient mixing time and water addition to ensure all raw materials and water are thoroughly mixed and have consistent moisture content. Uneven mixing will lead to uneven strength within the brick blank and easy cracking.

II. Forming Stage: Imparting Shape and Initial Strength

The forming stage determines the density, dimensional accuracy, and appearance of the brick blank.

Monitoring of forming pressure: The forming pressure of the brick machine must be stable within the set range. Insufficient pressure results in low density and poor strength; excessive or fluctuating pressure may cause hidden cracks or dimensional deviations. The pressure system needs to be regularly inspected, recorded, and calibrated.

Standardized management of molds: Molds are the "master templates" of the bricks, and their condition directly affects the product's appearance. Molds need to be regularly inspected for wear and deformation, and repaired or replaced promptly. Molds must be cleaned before and after each shift to ensure smooth demolding and prevent material sticking and damaging the brick blanks.

Control of material distribution uniformity: Ensure that the raw materials are evenly and sufficiently filled into the molds to avoid localized material shortages or uneven density. This is crucial for preventing chipped corners and uneven strength in the bricks.

III. Curing Stage: Guaranteeing Strength Development

After the brick blanks are formed, curing is a crucial chemical reaction process that determines their final strength. Curing (Pre-curing) Management: Newly formed wet brick blanks must be left to stand in a sheltered, shaded, and humid environment for a sufficient period (usually 12-24 hours) to allow for even moisture distribution and initial hardening. This is a crucial step in preventing cracking.

Systematic Watering and Curing: Develop clear watering and curing procedures (such as start time, frequency, and water volume) based on climate and season, and strictly adhere to them. Ensure that the brick blanks maintain appropriate humidity during the critical period of strength development (especially the first 3-7 days). Insufficient curing is a common main reason for substandard strength.

Curing Environment Control: Plan a dedicated curing area with a level ground surface and conditions for shading and rain protection. Different batches of brick blanks should be clearly separated into different areas for easy management and recording of the curing cycle.

IV. Inspection and Traceability: Closed-loop Management and Continuous Improvement

Quality control must form a closed loop, relying on data-driven decision-making.

Setting Process Inspection Points: Set inspection points after mixing, after molding, and during the middle of the curing process. For example, randomly inspect the appearance, dimensions, and integrity of wet blanks, and quickly test the temperature and humidity of the curing area.

Regular Finished Product Inspection: According to national standards or customer requirements, regularly send finished brick samples to professional institutions for testing key indicators such as compressive strength and water absorption. Use authoritative data to verify whether the production process is continuously under control.

Establish a Traceability System: Create a simple file for each batch of products, recording the batch number of raw materials used, production date, key process parameters (such as pressure value), curing records, and final inspection results. If a quality problem occurs, it can be quickly and accurately traced back to the problematic link, enabling targeted improvements.

Summary: Standardized Operations, Data-Driven Decisions, and Full Employee Participation

Quality control is not the responsibility of the quality inspector alone, but a systematic project that requires the participation of all employees. Managers should clarify the quality standards and operating procedures 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 these four core points—raw material proportioning, molding pressure, curing management, and inspection and traceability—are effectively controlled, consistently producing high-quality bricks will be a natural result.