Analysis of Common Quality Problems in Bricks and Preventive Measures

Analysis of Common Quality Problems in Bricks and Preventive Measures

Cracking, chipping, and insufficient strength in bricks after production not only affect sales but also expose oversights in the production process. Systematic analysis of the causes and implementation of targeted preventive measures are key to stabilizing product quality.

I. Insufficient Strength and Brittleness

Main Causes:

Raw Material and Proportioning Issues: Excessive mud content or impurities in raw materials; insufficient or ineffective addition of cement or other binding materials; inaccurate or unstable raw material proportions.

Insufficient Molding Pressure: Insufficient or unstable pressure in the brick-making machine leads to a loose internal structure in the brick blank.

Improper Curing: Insufficient watering or curing time during the curing period, or poor curing environment (temperature and humidity), resulting in incomplete hydration of the bricks.

Preventive Measures:

Strictly Control Raw Materials: Use clean, qualified raw materials and strictly adhere to the tested proportions for weighing and feeding.

Ensure Molding Pressure: Regularly check and calibrate the brick-making machine's pressure system to ensure that each brick reaches the specified density.

Standardized Curing Procedures: Establish and strictly implement a curing system to ensure sufficient moisture retention for the brick blanks during critical periods.

II. Cracking (Surface Cracks or Through-Cracks)

Main Causes:

Excessive Drying: After molding, exposure to direct sunlight or strong winds causes surface moisture to evaporate much faster than internal moisture, resulting in uneven shrinkage and cracking.

Poor Raw Material Plasticity: Insufficient fine-particle content in the raw materials or uneven mixing leads to poor adhesion after molding.

Handling Damage: Excessive force during demolding, handling, or stacking can cause internal damage to the still-soft brick blanks.

Preventive Measures:

Avoid Rapid Water Loss: Newly molded wet bricks must be placed in a cool, windless place to cure, strictly avoiding direct sunlight and wind exposure.

Optimize Raw Materials and Mixing: Ensure the raw materials have a certain degree of plasticity and ensure thorough and uniform mixing.

Standardized Operation: Train employees to handle bricks gently, especially during demolding and initial stacking.

III. Large Dimensional Deviations, Missing Corners and Edges

Main Causes:

* **Mold Wear or Deformation:** After prolonged use, the mold size increases or its edges and corners become damaged.

* **Uneven Material Distribution:** Uneven filling of the mold with raw material, resulting in localized material shortages.

* **Poor Demolding:** Inadequate mold cleaning and maintenance leads to material sticking and damage to the brick blank.

Preventive Measures:

* **Strengthen Mold Management:** Regularly inspect and measure mold dimensions and wear, and repair or replace them promptly.

* **Ensure Uniform Material Distribution:** Adjust the material distribution equipment to ensure the raw material is evenly distributed across the mold.

* **Proper Mold Maintenance:** Clean the mold every shift and apply release agent periodically (if necessary).

IV. Uneven Appearance and Color, Loose Surface

Main Causes:

* **Uneven Raw Material Mixing:** Insufficient mixing time or improper mixing methods result in uneven raw material distribution.

* **Impurities:** Impurities of other colors are mixed into the raw material.

* **Insufficient Molding Pressure:** The surface cannot be compacted.

Preventive Measures:

* **Ensure Thorough Mixing:** Ensure sufficient mixing time and use the correct mixing method.

Strengthen raw material screening: Sieve or select raw materials to remove impurities.

Inspect the molding process: Ensure pressure meets standards and molding is complete.

Summary: Prevention is key; achieve full-process control. Almost all quality problems can be traced back to the production process. The most effective strategy is "prevention first, process control." This requires managers to establish quality standards and control points throughout the entire process, from raw materials, proportioning, molding to curing, and to check and record the implementation of each step. When problems occur, they should be quickly traced back to the specific step for correction. Only by integrating quality awareness into every action of daily production through standardized operations and continuous employee training can high-quality bricks be consistently produced.