How to ensure the irregular-shaped refractory bricks match customer requirements

How to ensure that shaped refractory bricks meet customer requirements

Shaped refractory bricks generally refer to special positions in industrial kilns with irregular shapes. In situations where conventional refractory bricks cannot be constructed, customized refractory bricks of different shapes are needed according to the specific usage scenario. Irregular-shaped bricks are also a type of refractory bricks, but their shape is irregular compared to ordinary refractory bricks. Irregular bricks have important applications in special parts of industrial kilns.

During international business, when we receive an order from a customer for irregular-shaped bricks, how can we ensure that the produced irregular-shaped bricks meet the customer’s customization requirements from production arrangement to shipment? As a factory specializing in the production of refractory materials for over 20 years, we at Henan Fireramo Industrial Co., Ltd. are glad to share our experience on how we control the production and before shipment inspection of irregular-shaped bricks.

After we received an order from the customer for irregular-shaped zirconia corundum refractory bricks applied in glass kilns, the customer required drawing paper as follows:

According to the drawings, what we can check is that it requires the assembly of eight irregular bricks to form a set of circular components.

Usually, we have the following steps to ensure consistency between the product and customer requirements:

Professional customization of molds

Because of the particular size of irregular-shaped bricks, their production requires the use of specially customized molds. The shape of the irregular-shaped bricks is customized according to the customer’s needs and the specific application situation. Here, we first customized a special mold based on the customer’s drawing size of zirconium corundum irregular-shaped bricks.

Standardized Raw Material Selection & Precision in Mixing and Forming

Because irregular shaped bricks need to be proportioned according to the specific application situation, and then made into different shaped irregular bricks based on the raw materials in the proportioning. Our factory uses high-quality aluminum oxide powder and zircon sand as raw materials for zirconia corundum bricks, and strictly proportions them according to the chemical indicators required by customers. Consistency begins with the selection of high-quality raw materials. Establish stringent standards for raw material acceptance, considering factors such as chemical composition, particle size distribution, and thermal properties. Regularly audit and update these standards to adapt to evolving industry requirements.

Meantime product mixing and forming processes are also critical stages in zirconia corundum refractory brick manufacturing. Employ precision machinery to ensure uniform mixing of raw materials, eliminating variations in composition. We have Invested in advanced forming technologies to create special-shaped bricks with precise dimensions, minimizing deviations from customer specifications.

Controlled Drying and Curing

Proper drying and curing are essential to prevent defects and ensure the structural integrity of irregular-shaped zirconia corundum refractory bricks. Implement controlled drying processes to eliminate moisture uniformly, preventing cracks or warping. Develop standardized curing procedures to enhance the bricks’ strength and resistance to thermal stress.

Consistent Firing Techniques

Firing is a pivotal step in the production of zirconia corundum refractory bricks. Establish and adhere to consistent firing techniques, including temperature profiles and duration, to achieve the desired material properties. Regularly monitor and calibrate kilns to maintain optimal firing conditions.

Dimensional measurement after production completion

After the product is produced, before packaging, we will assign dedicated tracking personnel and our factory engineers to conduct comprehensive measurements of zirconia corundum irregular-shaped bricks, to ensure that the various dimensions of the product are consistent with customer requirements and, in the meantime, timely and accurately record the measurement results.

In sort, with high-quality technical production and perfect service, we at Henan Fireramo Industrial Co., Ltd. welcome both domestic and foreign customers to contact us at any time.