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2025 Brictec Iraq Clay Sintered Brick KTB Project
Construction Process of Clay Brick Plant
I. Project Overview
The construction of a clay sintered brick plant is a systematic project consisting of several key sections: raw material yard, forming workshop, drying system, tunnel kiln firing system, finished brick packaging line, and supporting utilities.
The entire process follows the principles of scientific planning, phased construction, quality first, and safety control, ensuring stable operation after commissioning.
Our product pricing is customized according to your production capacity requirements and detailed project drawings, ensuring the most cost-effective solution for your brick plant.
II. General Construction Workflow
1. Survey and Design Phase
(1) Geological investigation and foundation bearing tests;
(2) Plant layout and functional zoning design;
(3) Determination of tunnel kiln orientation and foundation layout;
(4) Completion of civil, structural, and equipment design drawings.
2. Civil Foundation Construction
(1) Site leveling and road hardening;
(2) Excavation and concrete pouring;
(3) Installation of embedded parts and kiln foundation;
(4) Application of moisture-proof layers.
3. Equipment Installation and Commissioning
(1) Installation of raw material line, brick forming units, and stacking robots;
(2) Installation of drying ducts, fans, and hot air systems;
(3) Tunnel kiln masonry and burner system setup;
(4) PLC automation and sensor calibration;
(5) Unloading and packaging systems commissioning.
4. Trial Production and Validation
(1) No-load testing → Kiln drying → Pilot firing;
(2) Optimization of firing curves and temperature zones;
(3) Verification of water absorption, compressive strength, and surface quality.
III. Tunnel Kiln Construction Process (Key Section)
The tunnel kiln is the core unit of brick firing, and its construction quality directly determines production efficiency and product performance.
1. Kiln Foundation
(1) Bearing capacity ≥ 180kPa; flat and crack-free concrete base (≥ C30 grade);
(2) Reinforced with a waterproof insulation layer;
(3) Track elevation error ≤ 3mm.
2. Kiln Body Masonry
(1) Multi-layer composite structure using high-alumina bricks and insulation materials;
(2) Vault-type roof with steel frame support;
(3) Floor bricks made of wear-resistant materials with smooth leveling;
(4) Mortar joints ≤ 3mm, bonded with high-temperature adhesives.
3. Combustion & Ventilation System
(1) Equipped with burners, air ducts, and exhaust fans;
(2) Controlled via PLC with temperature zone sensors;
(3) Sealed ducting prevents backflow and gas leakage.
4. Kiln Car and Track System
(1) Kiln cars made of heat-resistant steel;
(2) Flatness tolerance ≤ 2mm;
(3) Tracks aligned precisely for stable operation.
5. Kiln Drying and Trial Operation
(1) Temperature rise ≤ 20°C/h in stages;
(2) Full drying cycle: 10-15 days;
(3) Continuous monitoring of stress and temperature distribution;
(4) Trial firing follows successful drying.
IV. Quality Control Key Points
|
Control Item |
Requirement |
Inspection Standard |
|
Refractory Material |
Al2O3 ≥ 55% |
Sampling & certification |
|
Masonry Accuracy |
Joint 2-3mm, vault deviation ≤5mm |
Field measurement |
|
Track Alignment |
Level error ≤3mm, alignment ≤2mm |
Laser inspection |
|
Thermal Insulation |
Outer wall temp ≤65°C |
Thermal imaging |
|
Combustion System |
No gas leakage, uniform flame |
On-site commissioning |
|
Roof Stability |
No deformation or displacement |
Dynamic monitoring |
V. Acceptance and Optimization
1. Full inspection of kiln geometry, sealing, and control systems;
2. Submission of construction and inspection records;
3. Monitoring of energy consumption and product quality during test run;
4. Continuous optimization of firing parameters for best efficiency.
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