BRICTEC Engineering

Project Update | Brictec MUSK Project Engineering Progress | Drying Chamber

I. Project Overview

The MUSK project is located in Kirkuk, Iraq, and is planned to build a modern block production base with a daily output of 800 tons. The product range covers load‑bearing blocks, standard bricks, and partition blocks, meeting the material requirements of various local building structures and providing a stable, high‑quality supply of materials for regional urban development.

II. Engineering Progress

Project update for September 2026:

Recently, frequent progress reports have come from the MUSK overseas EPC project construction site. The core process unit – the drying chamber – is currently undergoing vigorous civil construction work, with all on‑site activities steadily accelerating.

At present, multiple key procedures are being carried out simultaneously, including concrete pouring for the drying chamber roof, floor slab hardening and pouring, and main wall masonry. The Brictec construction team has planned the work scientifically, rationally allocated manpower, machinery, and building materials, and strictly controlled every construction detail – such as wall verticality, concrete pouring thickness, and curing periods – in accordance with drawing standards. Safety management is fully implemented throughout the entire process to ensure that civil construction quality meets the required standards and remains controllable.

As the core process unit of the entire fired brick production line, the drying chamber will later undertake the critical tasks of gradient temperature control and uniform moisture removal for green bricks. Its construction quality directly determines the subsequent operational stability and finished product quality of the entire production line. The smooth progress of this civil construction phase has paved the way for the next stage – the installation of ancillary equipment for the hot‑air circulation system in the drying chamber.

The project team will continue to stay focused on the schedule, coordinate all resources in a well‑organized manner, strictly control the construction window, and make every effort to steadily advance toward the goal of on‑time project completion and commissioning.

Author: Brictec Weijiangfei
Technical Engineering: Ms. Han
Editor: Wendy Luo
Copyright: Xi'an Brictec engineering Co., Ltd.


#brickmakingmachine #tunnelkiln #bricks #brickmaker #brick #redbricks #brickmaker #clay #brickbuilder #brickwork #bricksmachine #brickmakingmachine #claybrickmakingmachine #redbrickmakingmachine #brickfactory #brickpackagingmachine #automaticbrickmakingmachine

Xi'an Brictec engineering Co., Ltd. (abbreviation: Xi'an Brictec) was founded in 2011. It employs senior Italian engineers to work with domestic experts, creating a strong technical team by combing the European and Chinese technologies. The company is devoted to provide clients multiple professional brick making solutions, including building structure bricks, decorative bricks,wall cladding bricks, paver and dry press bricks, etc.
🌐Website: en.brictec.com/
📩 E-mail: info@brictec.com
📞WhatsApp:+86 181 8262 2677
Xi'an Brictec Engineering Co.,LTD
Address: [Zhongxing Industrial Park, No. 10, Tangyan South Road, High-tech Zone, Xi'an]

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5 days ago | [YT] | 4

BRICTEC Engineering

A Retrofit Solution for Mixer Blades in Brick Manufacturing: Split Blade Design for Enhanced Durability and Safety

1. Background

In many brick plants, the mixer blades (also known as stirring knives or paddles) frequently bend or break during operation. The broken blades, carried by the belt conveyor into the extruder, often damage the scraper plates, scraper shafts, augers, or even the mud cylinder itself, causing major mechanical failures and production stoppages. These incidents not only increase maintenance costs and repair time but also severely reduce output, undermining overall plant profitability.


2. Core Methods & Mechanism Anatomy

2.1 Root Cause Analysis

Field observations and failure analysis identified two primary causes of blade breakage:

• Insufficient structural strength under impact: The original blade shank was a Φ22 mm screw rod. When the mixer encountered hard foreign objects such as broken bricks, stones, or metal debris, the screw rod would easily bend or snap under sudden impact loads.
• Loosening of the shank nut: The fixing nut on the blade shank tended to loosen during vibration, altering the blade's angle relative to the mixing shaft. This change in geometry caused uneven stress distribution, leading to premature fatigue and fracture.


2.2 Proposed Improvement: Split Blade Design

The conventional one‑piece straight‑shank blades were completely replaced with a split‑type design, consisting of two separate components:

• Blade base (holder) – cut from 20 mm thick steel plate, precisely welded onto the mixing shaft at the original helical angle that matches the shaft's spiral pitch.
• Replaceable blade tip – also cut from 20 mm steel plate, attached to the base with two M12×30 bolts.

This separation allows the blade tip—which bears the brunt of wear and impact—to be easily exchanged without removing the entire base or dismantling the shaft.

2.3 Why It Works

• The bolted connection provides a degree of flexibility under shock, absorbing impact energy better than a rigid one‑piece shank.
• The blade angle is fixed by the precisely welded base, eliminating the risk of nut loosening and angle drift.
• The use of 20 mm flat steel (instead of a thin screw rod) increases cross‑sectional area and bending resistance, making the blade far less susceptible to plastic deformation.


3. Practical Recommendations

For plants considering a similar retrofit, the following step‑by‑step process is recommended:

• Disassemble and measure – Remove the existing blades and carefully record the original helical angle and axial position of each blade relative to the mixing shaft.
• Fabricate new components – Cut both the base plates and blade tips from 20 mm high‑strength steel plate (e.g., Q345 or equivalent). Machine bolt holes accurately.
• Weld the bases – Position and weld each base onto the shaft, ensuring the correct helical angle and pitch. Use a jig or template to maintain consistency across all blades.
• Attach blade tips – Secure each tip with two M12×30 grade 8.8 bolts, applying thread‑locking compound to prevent loosening under vibration.
• Test run – Operate the mixer under no‑load, then gradually add material, monitoring for unusual noise or imbalance. Check bolt tightness after the first shift.
• Periodic inspection – Replace worn blade tips proactively; inspect bolt torque and base weld integrity during routine maintenance.


4. Summary

• The split‑blade retrofit completely eliminates blade breakage—over three years of field use, no bent or broken blades have been reported in the implementing plant.
• The design reduces downtime, simplifies maintenance (only the tip needs replacement), lowers material consumption, and cuts repair costs.
• With a modest upfront investment in steel plate and machining, plants can achieve significant long‑term savings and improve production reliability.
• Note: The reported success is based on a single plant’s experience; adaptation to other mixer models or material types should be validated with local conditions.


#brickmakingmachine #tunnelkiln #bricks #brickmaker #brick #redbricks #brickmaker #clay #brickbuilder #brickwork #bricksmachine #brickmakingmachine #claybrickmakingmachine #redbrickmakingmachine #brickfactory #brickpackagingmachine #automaticbrickmakingmachine

Xi'an Brictec engineering Co., Ltd. (abbreviation: Xi'an Brictec) was founded in 2011. It employs senior Italian engineers to work with domestic experts, creating a strong technical team by combing the European and Chinese technologies. The company is devoted to provide clients multiple professional brick making solutions, including building structure bricks, decorative bricks,wall cladding bricks, paver and dry press bricks, etc.
🌐Website: en.brictec.com/
📩 E-mail: info@brictec.com
📞WhatsApp:+86 181 8262 2677
Xi'an Brictec Engineering Co.,LTD
Address: [Zhongxing Industrial Park, No. 10, Tangyan South Road, High-tech Zone, Xi'an]

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1 month ago | [YT] | 6

BRICTEC Engineering

Diagnosing and Correcting Common Defects in Semi-Hard Plastic Extrusion Forming of Roof Tiles

1. Background & Challenges

Semi-hard plastic vacuum extrusion is an advanced forming process for clay flat tiles, offering lower forming moisture (16–18% dry basis), higher green strength (allowing stacking up to 0.94 m without deformation), shortened drying cycles (30–50% reduction), simplified workflows, and significant savings in wood pallets and infrastructure. However, many manufacturers fail to master the critical forming parameters, leading to recurring defects—bending, twisting, scalloping, warpage, and cracking—that undermine product quality and economic returns. This article synthesizes field experience from over 300 plants using JYK-310 and JYK-265 extruders, and provides systematic troubleshooting guidelines.

2. Core Methods & Mechanism Anatomy

2.1 Raw Material Prerequisites

• Requirement: Drying sensitivity coefficient < 2; proper particle size distribution; clay free from pebbles or impurities.
• Failure mode: If these conditions are unmet, cracking appears during forming and drying.
• Original argument: Raw material is the prerequisite.

2.2 Equipment Installation Precision

• The extruder axis must be horizontally level; the main shaft must be centered in the mud cylinder (tolerance ±0.5 mm); the die (mouth) and compression cylinder must be aligned; the cutting table must be parallel to the extrusion axis.
• Misalignment directly causes unidirectional bending or twisting.

2.3 Defect-Specific Mechanisms and Corrections


2.4 Diagnostic Tool: Velocity Profile Measurement

A practical method: place four steel wires at the die exit to split the profile into five equal-width strips; extrude for a fixed time (≈1 m) and measure each sub‑strip’s length. The tolerance (< 3–5%) reveals velocity non‑uniformity, which is the root cause of many cracks and warpage.

3. Practical Recommendations

• Pre‑start checks: Verify raw material properties (sensitivity, particle size, impurities).
• Installation verification: Use dial gauges and spirit levels to confirm shaft centering (≤0.5 mm), die alignment, and table parallelism before first run.
• Velocity profiling: After installing a new die or changing raw materials, immediately perform the wire‑cut velocity test; record baseline data for each material batch.
• Maintenance schedule: Regularly inspect auger blades for wear and clean trapped clay between blades; replace liners if loose.
• Moisture consistency: Maintain forming moisture within ±1% of target; improve mixing intensity to avoid local variations.
• Drying management: In the early drying stage, cover tightly to prevent rapid surface dehydration; raise the drying floor and add waterproof padding to reduce bottom moisture.
• Operator training: Emphasize standard procedures for cutting, handling, and stacking to avoid additional warpage and handling cracks.

4. Summary

• Semi‑hard plastic extrusion is a high‑efficiency process, but its success hinges on raw material quality, precision equipment installation, and systematic velocity‑profile tuning.
• Most defects—bending, twisting, warpage, scalloping, and drying cracks—originate from velocity non‑uniformity or mechanical misalignment.
• The wire‑cut velocity test is a simple yet powerful diagnostic tool; maintaining ≤3–5% deviation across the section is the key quality control metric.


#brickmakingmachine #tunnelkiln #bricks #brickmaker #brick #redbricks #brickmaker #clay #brickbuilder #brickwork #bricksmachine #brickmakingmachine #claybrickmakingmachine #redbrickmakingmachine #brickfactory #brickpackagingmachine #automaticbrickmakingmachine

Xi'an Brictec engineering Co., Ltd. (abbreviation: Xi'an Brictec) was founded in 2011. It employs senior Italian engineers to work with domestic experts, creating a strong technical team by combing the European and Chinese technologies. The company is devoted to provide clients multiple professional brick making solutions, including building structure bricks, decorative bricks,wall cladding bricks, paver and dry press bricks, etc.
🌐Website: en.brictec.com/
📩 E-mail: info@brictec.com
📞WhatsApp:+86 181 8262 2677
Xi'an Brictec Engineering Co.,LTD
Address: [Zhongxing Industrial Park, No. 10, Tangyan South Road, High-tech Zone, Xi'an]

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1 month ago | [YT] | 9

BRICTEC Engineering

Brictec MUSK Production Line Project——July Site Construction Progress Report

The MUSK hollow block production line project with a daily output of 800 tons, undertaken by our company, is progressing steadily in civil construction. Multiple milestones have been achieved in the core foundations and track works of the kiln and drying chamber.

Current completed works are as follows:

Tracks for the first three spans of the tunnel kiln are fully installed, with the accompanying concrete floor slab pouring and curing completed;

Tracks for the first two spans of the drying chamber are laid, with the corresponding floor slab concrete pouring fully completed;

Masonry of the wall below the ring beam of the first span of the drying chamber is finished, and the staggered tooth joints (chamfered brickwork) for seismic tie columns have been simultaneously prepared and cast, ensuring the seismic structure meets the design standards.

At present, priority is given to rebar tying for the foundation of the aging yard, with the construction teams working in phased parallel operations to steadily advance the civil works.

According to the overall construction schedule, by the end of this month all foundations and track works for the drying chamber and tunnel kiln will be completed. After civil works are finished, the project will officially enter the equipment delivery and installation phase for kiln cars and the main machinery of the entire production line.

The project site is located in a high‑temperature and arid region of Iraq. The construction team strictly controls key processes throughout including concrete curing accuracy, masonry seismic techniques, and track installation flatness. They have overcome challenges such as extreme local climate and simultaneous multi‑trade operations, ensuring both quality and schedule compliance. This lays a solid foundation for the subsequent delivery and installation of the complete brick‑making equipment. Once the project is fully commissioned, it will supply high‑quality thermal insulation hollow blocks to the local market and support Iraq's infrastructure development.

Tunnel kiln tracks and floor slab concrete
Drying chamber tracks and floor slab concrete
Drying chamber wall masonry
Drying chamber wall‑column concrete pouring
Rebar tying for aging yard foundation


#brickmakingmachine #tunnelkiln #bricks #brickmaker #brick #redbricks #brickmaker #clay #brickbuilder #brickwork #bricksmachine #brickmakingmachine #claybrickmakingmachine #redbrickmakingmachine #brickfactory #brickpackagingmachine #automaticbrickmakingmachine

Xi'an Brictec engineering Co., Ltd. (abbreviation: Xi'an Brictec) was founded in 2011. It employs senior Italian engineers to work with domestic experts, creating a strong technical team by combing the European and Chinese technologies. The company is devoted to provide clients multiple professional brick making solutions, including building structure bricks, decorative bricks,wall cladding bricks, paver and dry press bricks, etc.
🌐Website: en.brictec.com/
📩 E-mail: info@brictec.com
📞WhatsApp:+86 181 8262 2677
Xi'an Brictec Engineering Co.,LTD
Address: [Zhongxing Industrial Park, No. 10, Tangyan South Road, High-tech Zone, Xi'an]

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1 month ago | [YT] | 4

BRICTEC Engineering

Brictec KTB Fired Brick Production Line Project
July Site Construction Progress Report

I. Project Introduction
Brictec KTB fired brick production line project. This project plans to construct three modern tunnel kiln fired brick production lines, to be carried out in three phases. After Phase I and Phase II are put into operation, the expected total daily output will reach 900 tons, mainly producing clay fired bricks with dimensions of 240×115×75 mm.

II. Current Progress
The KTB project is currently in the construction stage of the tunnel kiln roof and the drying chamber, as shown in the figures below.


#brickmakingmachine #tunnelkiln #bricks #brickmaker #brick #redbricks #brickmaker #clay #brickbuilder #brickwork #bricksmachine #brickmakingmachine #claybrickmakingmachine #redbrickmakingmachine #brickfactory #brickpackagingmachine #automaticbrickmakingmachine

Xi'an Brictec engineering Co., Ltd. (abbreviation: Xi'an Brictec) was founded in 2011. It employs senior Italian engineers to work with domestic experts, creating a strong technical team by combing the European and Chinese technologies. The company is devoted to provide clients multiple professional brick making solutions, including building structure bricks, decorative bricks,wall cladding bricks, paver and dry press bricks, etc.
🌐Website: en.brictec.com/
📩 E-mail: info@brictec.com
📞WhatsApp:+86 181 8262 2677
Xi'an Brictec Engineering Co.,LTD
Address: [Zhongxing Industrial Park, No. 10, Tangyan South Road, High-tech Zone, Xi'an]

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1 month ago | [YT] | 14

BRICTEC Engineering

Tunnel Kiln Low‑Calorific Sparse‑Setting Rapid‑Firing: Principles to Key Controls

Introduction：
The efficiency and quality of firing in a tunnel kiln depend on the coordinated control of temperature field, airflow field, and combustion reaction field. Although internal firing reduces external fuel consumption, fluctuations in calorific value and uneven oxygen supply tend to induce defects such as black core, pressure marks, and cracks. Production practice confirms that the four parameters—setting density, ventilation resistance, firing speed, and blended calorific value—are strongly nonlinearly coupled. Blind densification (dense setting) violates the seepage law of porous media, resulting in slower fire travel and aggravated black core. The so‑called “sparse setting” is actually a return to a reasonable porosity range, not an arbitrary reduction in brick count. Combined with a low‑calorific‑value strategy to cut costs and emissions, and rapid firing relying on the synergy of air and fire, these three elements form a systematic solution that balances output, quality, and environmental protection. This paper, from the perspectives of fluid mechanics and heat balance, outlines the theoretical basis, parameter boundaries, and common misunderstandings of this technique, providing concise references for on‑site process adjustments.

1. Setting Density and Ventilation Uniformity
The airflow through the gaps between green bricks behaves as forced convection in porous media. At normal setting density (220–250 pieces/m³), the porosity is about 35%–45%, with moderate resistance, sufficient oxygen supply for complete oxidation of internal carbon, and heat uniformly carried by the airflow.
If the density increases above 280 pieces/m³, porosity drops below 25%, resistance rises quadratically, and the main airflow short‑circuits along the outer edges and longitudinal large gaps, forming an oxygen‑depleted dead zone inside the stack. In this zone, reductive pyrolysis occurs, leaving fixed carbon residue as black core; internal heat cannot be removed, causing local overheating, sticking, and deformation, while the outer layers cool due to excessive airflow, resulting in “overfired inside and underfired outside.” Therefore, sparse setting is essentially a return to the density range with minimum resistance and most uniform distribution, not a blind reduction in brick count.

2. Correct Interpretation of “Sparse Setting”
A common misconception is to treat sparse setting as the opposite of normal setting, assuming that the sparser the better for rapid firing. This error ignores the matching relationships among density, kiln cross‑section, fan capacity, and calorific value. In fact, sparse setting is specifically a correction to dense setting—removing the extra bricks added for densification and reverting to the thermally designed reference density. This reference already balances ventilation and loading capacity. Further sparseness reduces brick count per car and lowers output, while overly wide air passages cause heat loss and increase specific fuel consumption, counteracting rapid firing.
Proper operation should follow the “minimum effective ventilation cross‑section” principle: while ensuring each brick receives sufficient oxygen flow, narrow the longitudinal main air ducts as much as possible, forcing airflow through the fine gaps between bricks to achieve face‑type uniform air supply rather than line‑type short‑circuit exhaust. Stacking must strictly follow the layout drawings, controlling spacing and staggered joints.

3. Legacy Issues of Longitudinal Wide Air Ducts and Environmental Constraints
In the early promotion of coal‑gangue brickmaking, gangue had high calorific value (>1500 kcal/kg), so wide longitudinal ducts were adopted to dissipate excess heat—a compromise with very low thermal efficiency. Today, gangue calorific value has dropped to 600–900 kcal/kg. Retaining wide ducts brings three negative consequences:

Significant heat loss: High‑velocity air carries away large amounts of sensible heat, requiring supplementary fuel or higher internal blending to sustain sintering, directly increasing costs.

Exacerbated cross‑section temperature difference: High velocity in wide ducts leaves the stack interior almost airless, creating cross‑section temperature differences over 100°C and deteriorating product uniformity.

Artificially high flue‑gas oxygen content: Excess air mixes into the exhaust, often raising measured oxygen above environmental limits (e.g., >18%), easily misinterpreted as dilution cheating, while the actual combustion zone is oxygen‑deficient. This phenomenon is often wrongly blamed on “sparse setting and rapid firing,” when it is actually caused by improper stacking.
Correction: compress longitudinal ducts to the minimum process‑allowable width, forcing most air through the brick layers, ensuring full combustion while reducing the ineffective excess‑air coefficient to meet monitoring requirements.

4. Coordinated Parameter Adjustment for Low Calorific Value and Rapid Firing
Calorific value setting should be dynamically adjusted based on raw material mineralogy, kiln insulation, and car‑advance rhythm. The internal calorific value must meet the minimum heat required for volatile release in the preheating zone and solid‑state reactions in the firing zone, generally controlled at 750–950 kcal/kg (depending on kiln type and brick thickness). Too low requires external fuel top‑up; too high leads to overfiring deformation during rapid firing.
Firing speed is governed by both ventilation intensity and heat release rate. Sparse setting reduces resistance, allowing higher airflow at the same fan power, thus accelerating fire travel. However, acceleration must be coordinated with the temperature curves of preheating, firing, and cooling—never blindly shorten car‑advance time. A reasonable target: reduce the car‑advance cycle from the usual 60 minutes to 45–50 minutes, ensuring the brick core reaches sintering temperature (950–1050°C) with sufficient soak time. In this range, both output and quality can be achieved; extreme compression below 40 minutes must be avoided.

5. Key Process Control Points

Standardized setting diagrams: Develop fixed stacking plans specific to each kiln, specifying brick spacing, duct dimensions, and layers; prohibit arbitrary changes.

Real‑time calorific value testing: Test the lower calorific value of each coal‑gangue batch, dynamically adjust internal blending ratio, and keep kiln‑entry calorific value fluctuation within ±50 kcal/kg.

Integrated air‑pressure and exhaust control: Adjust branch damper openings according to car position to maintain proper pressure gradients along each section and avoid local turbulence.

Black‑core cross‑section inspection: Regularly break out‑of‑kiln bricks for cross‑section checks; if black core exceeds tolerance, first investigate ventilation uniformity, not simply blame the kiln operator.

Conclusion
Low‑calorific‑value sparse‑setting rapid firing is not a fixed template but a flexible optimization framework based on fluid mechanics, heat transfer, and reaction kinetics. Its effective implementation requires technicians to deeply understand the intrinsic coupling among “setting, air, fire, and material” and to adapt flexibly to raw‑material changes and kiln conditions. Abandoning the crude habits of “densify for more output” and “widen ducts for heat dissipation,” and returning to data‑driven, refined process management, enables a sustainable optimum under the four constraints of high output, good quality, low consumption, and environmental compliance. The principles outlined here aim to provide clear, practical, and verifiable decision references for production floors.

#brickmakingmachine #tunnelkiln #bricks #brickmaker #brick #redbricks #brickmaker #clay #brickbuilder #brickwork #bricksmachine #brickmakingmachine #claybrickmakingmachine #redbrickmakingmachine #brickfactory #brickpackagingmachine #automaticbrickmakingmachine

Xi'an Brictec engineering Co., Ltd. (abbreviation: Xi'an Brictec) was founded in 2011. It employs senior Italian engineers to work with domestic experts, creating a strong technical team by combing the European and Chinese technologies. The company is devoted to provide clients multiple professional brick making solutions, including building structure bricks, decorative bricks,wall cladding bricks, paver and dry press bricks, etc.
🌐Website: en.brictec.com/
📩 E-mail: info@brictec.com
📞WhatsApp:+86 181 8262 2677
Xi'an Brictec Engineering Co.,LTD
Address: [Zhongxing Industrial Park, No. 10, Tangyan South Road, High-tech Zone, Xi'an]

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2 months ago | [YT] | 3

BRICTEC Engineering

Full Construction Technical Standards for Kiln Car Manufacturing in Fired Brick Plants

1 General Provisions

1.1 Scope of Application
These standards apply to the complete process of new fabrication and refurbishment of dedicated kiln cars for tunnel kiln fired brick production lines, covering all procedures: kiln car structural design, steel structure welding, base leveling, refractory and insulating layer masonry, running gear assembly, sealing structure installation, complete car commissioning, and factory acceptance. Kiln cars operate under prolonged high temperatures (maximum kiln temperature 1050°C), alternating thermal cycles, heavy-load pushing, and track reciprocating motion. These standards specifically address common industry issues such as frame deformation, lining cracking and heat leakage, wheel jamming, sand seal air leakage, car deviation, and cross‑flow affecting brick firing quality.

1.2 Basic Technical Requirements

• Rated load per car: meeting full‑load stacking of fired bricks, with a single‑car capacity ≥35 t.
• Operating conditions: adapted to thermal cycles from ambient to 1050°C, with resistance to thermal shock, extrusion, and deformation.
• Dimensional tolerances: overall dimensions, coaxiality of four wheels, and joint gaps all standardized to ensure interchangeability across the entire kiln car fleet.
• Service life: steel frame service life ≥8 years under normal conditions; major overhaul interval for refractory lining ≥2 years.



2 Technical Standards for Kiln Car Structural Design

2.1 Overall Structural Design
The kiln car adopts a main beam + secondary beam + deck plate frame steel structure, consisting of six modules: running mechanism, steel frame, thermal insulation base, refractory load‑bearing surface, side sand seal systems, and front/rear end face sealing. Simplification of structure or reduction of section thickness is prohibited.

2.2 Steel Section Selection Standards

• Main load‑bearing beams: National standard 30# thickened I‑beams, thickness ≥14 mm, to resist longitudinal pushing forces and vertical loads, preventing bending deformation under prolonged heavy load.
• Transverse secondary beams: 20# channel steel, spacing controlled at 400 mm ±20 mm, to evenly distribute deck loads.
• Frame bottom plate: 6 mm thick checkered steel plate, fully welded to prevent insulation layer detachment.
• Towing end plate: 20 mm thick reinforced steel plate, positioned at the continuous pushing point to avoid end extrusion deformation.
• Sand seal side plates: 8 mm thick heat‑resistant steel plate, with thermal expansion clearances to prevent warping at high temperature.

2.3 Thermal Expansion and Anti‑Deviation Design

• Bidirectional expansion joints are in both refractory lining and steel structure to relieve high‑temperature expansion stresses.
• Wheels adopt standard gauge design with four‑wheel coaxial layout to inherently avoid deviation and rail gnawing.
• An insulating protection plate is installed under the frame to shield running components (axles, bearings, etc.) from kiln heat radiation.



3 Welding Construction Standards for Steel Frame

3.1 Pre‑Welding Preparation
All sections shall be deburred, and oxides, rust, and grease removed after cutting. The frame shall be assembled and positioned on a jig platform to ensure overall length and width tolerance ≤ ±3 mm. Assembly without a jig is forbidden to prevent inherent distortion.

3.2 Welding Process Requirements

• Welding method: CO₂ gas‑shielded welding, with full and firm weld beads. Double‑layer full welding at connections between main and secondary beams; spot welding or intermittent welding is prohibited.
• Weld quality: weld height ≥6 mm, free from slag inclusions, porosity, cracks, undercut, etc. Critical load‑bearing welds shall be 100% visually and non‑destructively inspected.
• Stress relief: after complete welding, the car shall be left to stand for 24 hours to release internal welding stresses; next processes shall not start immediately.
• Overall correction: after standing, the frame shall be leveled; flatness error ≤2 mm/m, diagonal height difference ≤3 mm.

3.3 Prohibited Defects
Splicing short pieces for main beams, concentrated welding on one side, and omitting stress relief are strictly forbidden. These practices will cause beam bending and weld cracking within 1‑3 months of service, leading to total car scrapping.



4 Technical Standards for Kiln Car Base (Steel Surface) Treatment

4.1 Post‑Welding Grinding and Cleaning
All welds shall be ground smooth to remove weld spatter and sharp edges. Dust, slag, and debris inside the frame shall be thoroughly cleaned to avoid affecting insulation layer adhesion and to prevent carbonization and blistering at high temperature.

4.2 Anti‑Corrosion and Thermal Insulation Base Coating

• External non‑heated areas of the frame shall be coated with high‑temperature‑resistant anti‑rust primer to prevent corrosion during outdoor storage.
• The upper surface (masonry base) shall be covered with a 5 mm thick high‑temperature refractory fiber felt to block heat conduction from steel structure to refractory bricks, reducing frame temperature and preventing softening deformation.
• Base leveling: the fiber felt shall be laid flat without wrinkles, ensuring a level substrate for subsequent insulation and refractory brick masonry to avoid uneven stress and cracking.

5 Masonry Construction Standards for Insulation Layer + Refractory Brick Lining (Core Procedure)
The deck adopts a three‑layer composite structure: bottom insulation layer + middle transition insulation layer + top refractory load‑bearing brick, total thickness ≥180 mm, laid in staggered joints; continuous vertical joints are prohibited.

5.1 First Layer: Lightweight Thermal Insulation Layer

• Material: lightweight clay insulating bricks, thickness 80 mm.
• Construction: wet‑laid with refractory mortar, joint thickness 2‑3 mm. Main function: isolate high kiln temperature to protect underlying steel frame and running wheels.
• Prohibition: ordinary red bricks are strictly forbidden as substitute; otherwise, bottom temperature will exceed limits and damage bearings and axles.

5.2 Second Layer: Refractory Fiber Insulation Transition Layer

• Material: 10 mm thick high‑temperature ceramic fiber blanket, fully laid over the entire surface.
• Function: further block heat conduction and buffer thermal expansion stresses of refractory bricks, reducing cracking probability.

5.3 Third Layer: High‑Alumina Refractory Load‑Bearing Brick (Top Layer)

• Material: second‑grade high‑alumina refractory bricks, thickness 90 mm, high compressive strength for direct stacking of green bricks.
• Masonry requirements: staggered joints between upper and lower layers; vertical through‑joints prohibited; joint thickness ≤2 mm, with full mortar filling without voids.
• Expansion joints: 15‑20 mm expansion gaps reserved in both transverse and longitudinal directions, filled with refractory fiber cotton to prevent brick arching and fracturing due to mutual extrusion at high temperature.

5.4 End Face Sealing Masonry Requirements
The front and rear end faces of the kiln car shall be built with a tongue‑and‑groove interlocking sealing structure instead of flat butt joints, reducing air leakage gaps between cars, stabilizing kiln firing temperature, and ensuring brick quality.









6. Concluding Remarks by Brictec
As the core transfer equipment in tunnel kiln fired brick production lines, the construction quality of kiln cars directly determines kiln energy consumption, finished brick yield, and operational maintenance costs. Strict adherence to the full‑process technical standards – from structural design, steel welding, base treatment, refractory lining, running gear assembly to complete car commissioning – can thoroughly eliminate frequent failures such as deformation, heat leakage, deviation, and air cross‑flow, effectively extending service life and ensuring continuous, stable, and low‑cost operation of the entire fired brick production line.


#brickmakingmachine #tunnelkiln #bricks #brickmaker #brick #redbricks #brickmaker #clay #brickbuilder #brickwork #bricksmachine #brickmakingmachine #claybrickmakingmachine #redbrickmakingmachine #brickfactory #brickpackagingmachine #automaticbrickmakingmachine

Xi'an Brictec engineering Co., Ltd. (abbreviation: Xi'an Brictec) was founded in 2011. It employs senior Italian engineers to work with domestic experts, creating a strong technical team by combing the European and Chinese technologies. The company is devoted to provide clients multiple professional brick making solutions, including building structure bricks, decorative bricks,wall cladding bricks, paver and dry press bricks, etc.
🌐Website: en.brictec.com/
📩 E-mail: info@brictec.com
📞WhatsApp:+86 181 8262 2677
Xi'an Brictec Engineering Co.,LTD
Address: [Zhongxing Industrial Park, No. 10, Tangyan South Road, High-tech Zone, Xi'an]

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2 months ago | [YT] | 5

BRICTEC Engineering

Kiln Car of Tunnel Kiln FAQs (Basic Knowledge)

Q1: Why is the kiln car considered the most critical and essential equipment in the tunnel kiln?
The kiln car is the most expensive and impactful auxiliary equipment in the tunnel kiln. It directly determines whether the kiln can operate continuously and stably, the quality of fired products, equipment failure rates, and overall energy consumption. The kiln walls and roof maintain constant temperatures with heat loss mainly from conduction, while the kiln car repeatedly enters and exits the high-temperature kiln, enduring severe thermal cycling. It is the primary source of heat loss, equipment failures, and production interruptions in the entire line.

Q2: What production problems can poor-quality kiln cars cause?
Inferior kiln cars easily lead to deformation, jerky movement, collision with kiln walls, slag accumulation on the track, and even collapse of the car itself. In severe cases, this forces the kiln to be shut down and the flame extinguished, interrupting continuous production, causing capacity losses, increased maintenance costs, higher reject rates, and significantly reducing the economic benefits of the production line.

Tunnel Kiln Kiln Car FAQs (Design and Material Selection)

Q1: What hidden risks arise from substandard steel material selection for kiln cars?
Some manufacturers use steel with negative dimensional tolerances and non‑compliant material properties. After commissioning, the kiln cars, subjected to long‑term stress and thermal cycling, undergo structural deformation, causing overall dimensional shifts. During operation, they rub against or collide with the walls, severely affecting the running precision inside the kiln.

Q2: What are the risks of non‑standard welding on the main beams and critical welds?
The main beams, secondary beams, and push‑car force points are core load‑bearing areas that require standard processes such as groove welding and fillet welding. If the manufacturer simplifies the welding procedure, the weld strength will be insufficient. After long‑term heavy‑load and high‑temperature operation, weld cracking and structural loosening may occur, and in extreme cases, kiln car collapse.

Q3: What are the hazards of skimpy welding on the bottom plate of the kiln car?
Large‑section kiln cars must have additional stiffening ribs, and the plates must be fully groove‑welded. If intermittent welding is used, heat will penetrate through the bottom, material will leak, and debris will fall and block the track inside the kiln, causing the kiln cars to run unevenly and jolt, thus affecting firing stability.

Q4: Why does the traditional welded structure of the sand seal plate often have problems, and how can it be improved?
When the sand seal plate is integrally welded to the main beam, the differential thermal expansion and contraction at high temperatures cause uneven stress, leading to deformation and jamming between the sand seal plate and the sand seal groove. The improved solution uses oval‑hole bolted movable connections, which allow self‑adjustment to thermal deformation, ensuring sealing effectiveness and smooth operation.




#brickmakingmachine #tunnelkiln #bricks #brickmaker #brick #redbricks #brickmaker #clay #brickbuilder #brickwork #bricksmachine #brickmakingmachine #claybrickmakingmachine #redbrickmakingmachine #brickfactory #brickpackagingmachine #automaticbrickmakingmachine

Xi'an Brictec engineering Co., Ltd. (abbreviation: Xi'an Brictec) was founded in 2011. It employs senior Italian engineers to work with domestic experts, creating a strong technical team by combing the European and Chinese technologies. The company is devoted to provide clients multiple professional brick making solutions, including building structure bricks, decorative bricks,wall cladding bricks, paver and dry press bricks, etc.
🌐Website: en.brictec.com/
📩 E-mail: info@brictec.com
📞WhatsApp:+86 181 8262 2677
Xi'an Brictec Engineering Co.,LTD
Address: [Zhongxing Industrial Park, No. 10, Tangyan South Road, High-tech Zone, Xi'an]

2 months ago | [YT] | 2

BRICTEC Engineering

Principle and Core Advantages of Drying Cyclone for Two-Stage Setting and Firing Production Line

The cyclone is a core piece of equipment in the drying section of a two-stage setting and firing production line for hollow blocks and thin-walled perforated bricks. It is primarily used for dynamic, uniform air distribution and replacement of humid air inside the drying chamber. It effectively solves problems such as uneven air blowing, imbalanced moisture content in green bodies, cracking, and deformation that occur with traditional drying methods. In particular, it is well-suited for the large-scale production of green bodies with high hole rates and high drying sensitivity.



I. Working Principle

The cyclone consists of a variable frequency motor, an impeller, an octagonal conical air duct, adjustable air deflectors, and a rack-and-pinion swing mechanism. The motor drives the impeller to rotate, creating negative pressure that extracts the drying medium and forms a circulating airflow. Precise air supply is achieved through adjustable gaps on both sides, and a 180° full-coverage sweeping motion is realized via mechanical oscillation, eliminating drying dead zones and ensuring uniform airflow and heat distribution to the green bodies. The equipment adopts a modular, interlocked design, where one drive unit can synchronously operate 4–5 cyclones, balancing drying performance with capital investment economy.



II. Stage-Specific Precise Drying Control (Core Technology)

The drying process of green bodies consists of three stages: heating, constant speed, and falling speed. Based on raw material test data, our company adopts a differentiated air and temperature control strategy for each stage to ensure drying stability:

1. Heating stage (gentle airflow with moisture retention): At the initial stage, green bodies are highly sensitive and prone to cracking. The system closes hot air supply, reduces fresh air intake, and uses a gentle airflow, constant-temperature, moisture-retention mode. Combined with precise speed regulation via the variable frequency drive, it prevents surface moisture from evaporating too quickly and causing cracks.

2. Constant-speed drying stage (balanced dehumidification): During this stage, internal and external moisture evaporate simultaneously. The variable frequency drive ensures stable air supply, rapidly and evenly removing free surface water, maintaining a balance between heat and moisture diffusion, and eliminating drying defects.

3. Falling-speed drying stage (steady-state finishing): Only a small amount of adsorbed moisture remains, and the green bodies no longer shrink or crack. The system operates steadily in a normal mode, thoroughly drying residual moisture to ensure the green body moisture content meets the standard without affecting the subsequent firing process.



III. Equipment Configuration and Process Parameters

The equipment is designed for standard drying kilns and drying cars, with parameters validated through mass production. Cyclone spacing is 4.3–5.2 m, suitable for standard green body trays up to 2 m in height. Four to five cyclones operate in unison with 180° full coverage. The annual production capacity of a single line can exceed 300,000 m³. The electrical control system uses Siemens PLCs and Schneider core components, providing stable operation and strong anti-interference capability, making it suitable for long-term, continuous, automated production.



IV. Equipment Optimization and Reliability Upgrades

In response to common long-term operational issues in the industry, three key optimizations have been made to the equipment, ensuring stable on-site operation and extremely low failure rates:

1. Lubrication optimization: An oil guide line has been added, and the oiling structure has been improved. Routine inspection and lubrication replenishment are convenient, effectively reducing wear on high-speed bearings.

2. Assembly optimization: Strict control over shaft system concentricity, combined with 24-hour full-load factory testing, eliminates resonance, vibration, and eccentric wear.

3. Material upgrade: The main shaft is made of high-strength alloy structural steel and heat-treated, offering high torque resistance and resistance to fracture, significantly enhancing mechanical stability of the equipment.



V. Brictec Summary

The entire drying cyclone system is custom-designed based on raw material testing, distinguishing it from general-purpose drying equipment. By first conducting raw material tests and then matching the process parameters, the system is precisely tailored to the production of highly sensitive thin-walled bricks and perforated bricks. It effectively reduces problems such as cracking, deformation, and uneven moisture content in green bodies, resulting in a high finished product rate and low operating and maintenance costs. It serves as a core guarantee for stable, energy-efficient, and high-capacity operation of fully automatic two-stage setting and firing production lines.

#brickmakingmachine #tunnelkiln #bricks #brickmaker #brick #redbricks #brickmaker #clay #brickbuilder #brickwork #bricksmachine #brickmakingmachine #claybrickmakingmachine #redbrickmakingmachine #brickfactory #brickpackagingmachine #automaticbrickmakingmachine

Xi'an Brictec engineering Co., Ltd. (abbreviation: Xi'an Brictec) was founded in 2011. It employs senior Italian engineers to work with domestic experts, creating a strong technical team by combing the European and Chinese technologies. The company is devoted to provide clients multiple professional brick making solutions, including building structure bricks, decorative bricks,wall cladding bricks, paver and dry press bricks, etc.
🌐Website: en.brictec.com/
📩 E-mail: info@brictec.com
📞WhatsApp:+86 181 8262 2677
Xi'an Brictec Engineering Co.,LTD
Address: [Zhongxing Industrial Park, No. 10, Tangyan South Road, High-tech Zone, Xi'an]

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2 months ago | [YT] | 8

BRICTEC Engineering

Latest Progress of Brictec's MUSK Project in Iraq
June 10, 2026 – Latest progress of Brictec's MUSK clay fired brick project in Iraq, a modern block production line with a daily output of 800 tons.
The project covers load bearing blocks, standard bricks and partition blocks, aiming to provide a stable and high quality supply of wall materials for various types of local building structures, thereby supporting the sustainable development of regional urban construction.
1. Steel structure of the main workshop has been completed;
2. Ground treatment of the workshop is ongoing;
3. Installation and pre-embedding of kiln car rails have started;
Other civil infrastructure works are progressing in an orderly manner…
Stay tuned for more project updates.



#brickmakingmachine #tunnelkiln #bricks #brickmaker #brick #redbricks #brickmaker #clay #brickbuilder #brickwork #bricksmachine #brickmakingmachine #claybrickmakingmachine #redbrickmakingmachine #brickfactory #brickpackagingmachine #automaticbrickmakingmachine

Xi'an Brictec engineering Co., Ltd. (abbreviation: Xi'an Brictec) was founded in 2011. It employs senior Italian engineers to work with domestic experts, creating a strong technical team by combing the European and Chinese technologies. The company is devoted to provide clients multiple professional brick making solutions, including building structure bricks, decorative bricks,wall cladding bricks, paver and dry press bricks, etc.
🌐Website: en.brictec.com/
📩 E-mail: info@brictec.com
📞WhatsApp:+86 181 8262 2677
Xi'an Brictec Engineering Co.,LTD
Address: [Zhongxing Industrial Park, No. 10, Tangyan South Road, High-tech Zone, Xi'an]

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1 2 3 4

2 months ago | [YT] | 12