Key to Quality Improvement: Raw Material Ratio and Vibration Time Control

Key to Quality Improvement: Raw Material Ratio and Vibration Time Control

The core of producing high-grade bricks lies in the precise control of raw material ratios and the meticulous mastery of the vibration molding process. These two aspects are like the "genes" and "skeleton" of the brick, jointly determining the strength, durability, and appearance quality of the final product.

Regarding raw material ratios, the key is to achieve "precision" and "stability." Cement, as a binder, must be used in a way that ensures strength while maintaining economy; its proportion usually needs to be strictly controlled. The gradation of aggregates (sand, stone chips) is crucial; a reasonable mix of coarse and fine particles is necessary to ensure density while avoiding voids. If admixtures such as fly ash are used, their activity and fineness must be stable, and the ratio needs to be adjusted accordingly when replacing part of the cement. The water-cement ratio is a sensitive factor affecting strength; too little water results in poor workability and honeycomb formation, while too much water significantly reduces strength. It is recommended to first determine the baseline ratio through laboratory samples, then finely adjust it in real time according to changes in the moisture content of the raw materials during production, and consistently conduct rapid testing on each batch of incoming raw materials to ensure a stable ratio.

The control of vibration time directly determines the density and uniformity of the brick blank. Insufficient vibration leads to a loose internal structure, substandard strength, and porous appearance; while excessive vibration may cause slurry segregation, aggregate settling, and watermarks on the surface, also affecting strength. The optimal vibration time is not a fixed value; it needs to be dynamically adjusted based on the workability of the mixture (dryness), brick thickness, and mold structure. For drier mixtures or thicker bricks, the vibration time should be appropriately extended; conversely, it can be shortened. During production, it is necessary to closely observe the integrity of the edges and corners, surface smoothness, and density of the cut surfaces of the brick blank after demolding, using these as intuitive criteria for adjusting the vibration time.

To achieve high-quality and stable production, a complete quality management chain must be established, from raw material testing, proportion calculation, mixing control to molding vibration. A traceable production record should be established for each batch of products, detailing key data such as raw material batch, proportion parameters, and vibration time. When product strength fluctuates, these records are the most valuable basis for analyzing the causes and making rapid adjustments. Ultimately, only by combining the precision of raw material proportions with the accuracy of vibration processes can truly qualified high-grade bricks be produced consistently and stably.