Brick Machine in Oman

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Brick-making machine molds are key components that determine the dimensional accuracy, appearance quality, and production efficiency of bricks. Maintenance must prioritize wear, deformation, and corrosion prevention, while also avoiding secondary damage to the molds caused by improper operation. The following are eight key considerations for mold maintenance, covering daily operation, assembly and disassembly, storage, and troubleshooting:

1. Cleaning and Maintenance: Avoid "Violent Cleaning" to Protect Mold Cavity Precision

Cleaning is fundamental to mold maintenance, but improper cleaning methods can directly scratch the cavity and damage surface smoothness. Important precautions include:

Avoid Scratching with Hard Tools: Stubborn buildup on the cavity wall and at the side mold joints should not be forcibly removed with hard tools such as rebar or steel spatulas. Instead, use a soft wire brush (diameter ≤ 0.3mm) or a nylon scraper for gentle cleaning. If hardened buildup occurs, soak it in 30-40°C warm water for 10-15 minutes to soften it before handling. This prevents scratches on the cavity surface, which can lead to chipped corners and rough edges on the brick surface.

Control the pressure of the high-pressure air gun: When cleaning dust from gaps, the pressure of the high-pressure air gun should be ≤ 0.6 MPa, and the distance between the gun nozzle and the mold surface should be ≥ 15 cm. This prevents the high-pressure airflow from impacting weak areas of the mold (such as the core of hollow bricks and the textured edges of special-shaped bricks), which could cause deformation or cracking of the component.

Dry sticky materials after cleaning: After producing highly sticky materials such as clay bricks and sludge bricks, if cleaning with warm water, thoroughly wipe the inner wall of the mold cavity and the surface of the guide pillars with a dry cloth to prevent residual moisture from causing mold rust (especially for cast iron molds). 2. Disassembly and Maintenance: Strictly follow the "sequence + force" approach to prevent component deformation.
Frequent mold disassembly and assembly (e.g., changing brick molds, deep cleaning) can lead to bent guide posts, misaligned side molds, and stripped bolts. The following guidelines must be followed:
Fixed assembly and disassembly sequence: During disassembly, follow the sequence "locating pins → side mold bolts → guide posts → bottom mold." During installation, proceed in reverse order (first install bottom mold → guide posts → side mold → locating pins). Avoid skipping steps and causing uneven force on components. (If you install the side mold first and then the guide posts, this may forcefully deform the guide posts.)
Bolt tightening requires "even force": The bolts connecting the side mold and bottom mold should be tightened gradually in a "diagonal cross" pattern, with each bolt applying the same torque (the standard mold bolt torque is 30-50 N·m, depending on the mold manual). Never tighten a single bolt all at once to prevent warping of the side mold due to excessive local force. (Warping can lead to excessive brick dimensional deviations.) Do not strike directly with a hammer: When installing guide pins or locating pins, if they become stuck, do not strike the mold body directly with a hammer. Check for foreign objects or misaligned components. If necessary, gently tap the end of the guide pin with a soft copper hammer to avoid denting the mold metal surface.

3. Lubrication and Maintenance: Choose the right lubricant to avoid "oil and dirt buildup."
Mold guide pins, locating pins, and sliding parts require regular lubrication to reduce friction and wear. However, improper lubricant selection and dosage can lead to dust adhesion and lubrication failure.

Select lubricant type based on needs:

For sliding parts such as guide pins and locating pins, use high-temperature grease (temperature resistance ≥ 150°C) to prevent grease loss due to high temperatures during production (such as the heat release of cement hydration).

For joints such as bolts and nuts, apply a small amount of graphite powder or anti-seize agent when lubricating, rather than ordinary grease (which tends to attract dust and make subsequent disassembly and assembly difficult). Control the amount of lubricant: Only a thin layer of grease (≤0.5mm thick) should be applied to the guide pin surface, sufficient to cover the metal surface. Excessive grease will attract raw material dust, forming "grease clumps" and increasing component friction. Only 1-2 drops of grease should be injected into the guide pin hole; there's no need to fill it completely.

Regularly clean old grease: After each mold change or deep cleaning, wipe off old grease and oil stains from the guide pin and bolts with a rag before reapplying new grease to prevent performance degradation caused by mixing of new and old grease. (For example, oxidized old grease can accelerate component corrosion.) IV. Storage and Maintenance: Strictly Control the Environment to Avoid "Rust and Deformation"
When molds are idle (especially during extended downtime), improper storage can lead to severe rust and deformation. Please note:

Specific storage requirements apply: The storage area must meet "humidity ≤ 60%, temperature 5-30°C, and be free of corrosive gases (such as ammonia and dust). Avoid open-air storage or storage near raw material warehouses or sewage pools (humidity and corrosive gases can accelerate mold corrosion). If the environment is humid, a desiccant (such as silica gel) should be placed in the storage area.

Molds must be "stored separately and supported and protected":

Disassembled mold components (side molds, bottom molds, and cores) must be individually wrapped in plastic film to prevent collisions and corner damage.

Base molds and large side molds must be placed flat on a supported iron rack (with support points ≤ 50 cm apart). Direct stacking is strictly prohibited (stacking can cause the bottom mold to deform under pressure, affecting the flatness of the brick).

Slender components such as cores should be hung vertically or placed horizontally on dedicated supports to prevent bending (for example, bending of the core of a hollow brick can cause the hole in the brick to shift). Long-term storage requires regular inspection: Molds that have been idle for more than 7 days should be unpacked and inspected every 15 days to check the condition of the anti-rust oil (if the anti-rust oil has dried out or fallen off, it needs to be re-cleaned and re-applied). Also, inspect components for rust and deformation, and address any problems promptly. (Minor rust can be sanded with fine sandpaper and then re-applied with anti-rust oil; deformation requires return to the factory for repair). 5. Maintenance: Real-time Monitoring of Production Abnormalities to Prevent Losses
Mold wear during production is often caused by abnormal operating conditions. Real-time adjustments are required by observing the brick's condition to prevent further wear.
Pay attention to abnormal brick signs: If the following conditions occur, immediately stop the machine, inspect the mold, and do not continue production:
"Chipped corners or burrs at fixed locations" on the brick surface: This could be scratches or buildup in the corresponding mold area. Clean the mold and inspect the cavity.
"Excessive dimensional deviation" (e.g., 1-2mm short) could be caused by warped side molds or loose locating pins. Retighten the bolts or adjust the positioning.
"Difficulty demolding" (bricks adhering to the inner wall of the cavity): In addition to cleaning the mold, check the cavity surface for rust (rust increases adhesion) and ensure the release agent is evenly applied (avoid overspray to avoid contaminating the raw material). Avoid "overproduction": Molds are designed for a rated production run (conventional molds can produce 50,000-80,000 standard bricks). Do not forcefully use them beyond their intended production run to meet production targets. When production runs approach their rated run, prepare spare molds and inspect existing molds for wear (for example, if the edge thickness of a side mold wears from 5mm to 3mm, replace it promptly to prevent irregular brick edges).

6. Material Compatibility: Different mold materials require different maintenance priorities.
Common mold materials for brick-making machines include cast iron (cost-effective, suitable for standard bricks), alloy steel (wear-resistant, suitable for special-shaped bricks/high-hardness materials), and stainless steel (rust-resistant, suitable for high-humidity materials). Maintenance requirements vary significantly depending on the material:

For cast iron molds, prioritize rust prevention. Wipe them dry after cleaning and apply a thick coat of rust-proof oil during storage. Avoid frequent temperature fluctuations (for example, exposing a high-temperature mold to cold water immediately after production) to prevent cracking. Alloy steel molds: Focus on preventing wear. When producing high-hardness raw materials (such as those containing a high concentration of quartz sand), reduce cleaning intervals to prevent hard particles from grinding against the inner cavity walls. Avoid sandpaper for polishing the cavity (alloy steel has a wear-resistant coating, which can damage it).
Stainless steel molds: Focus on preventing scratches. Do not use wire brushes when cleaning; use nylon cloth or a soft sponge instead. Avoid prolonged contact with acidic materials (such as industrial waste containing sulfate) to prevent corrosion and spotting on the stainless steel surface.
VII. Repair and Maintenance: Minor Damages Should Be Repaired Promptly, Major Damages Should Not Be Compromised
Minor mold damage can be repaired promptly to extend its service life, but improper repair can accelerate its deterioration. Note:
Minor Scratches/Abrasion: Local Repair: Minor scratches on the cavity surface (depth ≤ 0.2mm) can be filled with a mold-specific repair compound (such as epoxy resin repair compound). After curing, smooth the surface with fine sandpaper (800 grit or higher). Avoid allowing scratches to expand (scratches can cause material accumulation, creating a vicious cycle). Severe deformation/cracking: Self-repair is prohibited: If the mold has serious problems such as side mold warping (flatness deviation > 0.5mm), guide pillar bending, cavity cracking, etc., do not use a hammer to correct it or weld it to repair it yourself (welding will cause the mold material to be brittle, and correction may easily cause secondary deformation). It must be returned to the factory for heat treatment correction or laser welding repair by a professional manufacturer to ensure that the mold accuracy is restored.

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