3 Tools for Efficient Brick Management
Efficient brick management is an important part of quality refractory installation. An ideal system will do three things – Decrease material handling. Handling leaves small nicks and chips in the brick surface, negatively impacting quality. Increase safety by minimizing the physical handling of refractory. This results in less strain on employees and fewer minor injuries such as cuts, scrapes and bruises. Provide fast material delivery. This ensures there’s no unnecessary interruption for the bricking crew. Selecting the right tools to optimize brick delivery depends a lot on the size of the kiln. That’s why Bricking Solutions has developed several brick management options. Let’s see which one is the best fit for your operation. Bricking Machines For large diameter kilns, those 4 meters (13 feet) and up, the most effective tool for brick management will always be a skid steer, forklift or other small equipment. Being able to drive a full pallet of bricks from the staging area to the bricking machine is unquestionably the fastest delivery method with minimal brick handling. This type of delivery can be used with both our Kiln Bedding Cart and EZ Flexx50 Bricking Machine for fast, efficient material management. Additionally, our new Stair-Stepped Bricking Machine makes this process even more efficient for masons who prefer their bricks delivered from the keying side of the machine. This design provides additional clearance under the machine, allowing crews to drive support equipment underneath to deposit refractory materials. In situations where the bricking machine is following the bedding cart, brick can be easily accessed by both crews for increased productivity. Port-A-Trac Not every kiln is large enough to operate support equipment. In these situations, masons must look for alternative systems that still provide for minimal brick handling, increased safety and faster delivery. Our Port-A-Trac is a lightweight, modular system that allows two people to transport a full pallet of brick up kiln — and under the bricking machine — at approximately 2.5 meters per minute (8 feet per minute). The system increases material transport efficiency by more than 20% compared to roller conveyors, which might take up to an hour and a half with a crew of five. It also minimizes material handling, allowing the brick to be transported as a pallet, which avoids potential damage. The system comes with two 1.12-by-1.1-meter (44.25-by-43.5-inch) carts that are easy to maneuver in the tight space of smaller kilns. The carts can be loaded together and pulled with a winch or operated separately, giving crews the opportunity to reload one cart on the burn floor while the bedding crew takes brick from the other to increase efficiency. Conveyors Despite the benefits of transporting kiln brick in a pallet, there are situations where it must be moved individually, such as delivering it from the kiln floor to the deck of the bricking machine or feeding it to crews in very narrow kilns. In these situations, mechanical conveyors provide a more efficient solution than roller conveyors or so called “bucket brigades.” Our Incline Conveyor uses an electric motor to transfer brick and refractory from the kiln floor to the bricking machine with minimal effort. It can be used with any size bricking machine to deliver 15-20 bricks per minute. Using an incline conveyor eliminates the need for workers to carry materials up and down bricking machine ladders or pass materials overhead, both dangerous and physically demanding actions. For moving brick up kiln in narrow vessels — as well as taking debris out — our Hydraulic Conveyors provide a portable, easy-to-use solution. With a small crew, the system can be set up in as little as one to two hours, depending on length and site conditions. A 5-horsepower hydraulic drive moves up to 907 kilograms (2,000 pounds) in either direction at a rate of 45 meters per minute (150 feet per minute). This allows crews to remove material twice as fast as manual methods and a two-person crew can bring a full pallet of brick into the kiln in less than 10 minutes. Refractory Brick Delivery for Any Situation Inefficient refractory delivery can derail installation, so finding a method that fits your situation is important to overall quality. Many of the solutions here can be tailored to meet site specific requirements. Contact our team today to find the brick management system that’s right for your facility. LEARN MORE OR REQUEST PRICING
New Bricking Machine Delivers Efficient, Ergonomic Brick Management
Brick management has a significant impact on overall refractory installation efficiency. Up kiln or down, having bricks delivered in a way that’s comfortable for you and your crew increases productivity and safety. To increase brick management options, we recently released a new Stair-Stepped Bricking Machine. The new model retains the key benefits of our EZ Flexx50 Bricking Machine — which offers the lightest weight and highest load capacity on the market — but with a few tweaks to allow customers to tailor their refractory installation process for maximum comfort and efficiency. Here’s how the new bricking machine helps you step up refractory installation efficiency. Extra Clearance for More Brick Management Options The new stair-stepped design provides enough clearance to drive support equipment, such as skid steers or forklifts, underneath the machine. This allows crews to easily deposit refractory brick for the bedding crew and bricking machine on the keying side. This style of brick management minimizes brick handling and reduces the need for additional equipment, such as conveyors, to deliver brick. This, in turn, improves productivity and reduces brick damage and loss associated with the constant material handling. The 4- to 5-meter (13.1- to 16.4-foot) Stair-Stepped Bricking Machine offers approximately 213 centimeters (84 inches) of clearance. 5- to 6-meter (16.4- to 19.7- foot) models provide approximately 264 centimeters (104 inches). Actual clearance is dependent on machine configuration and kiln size. But don’t worry, the stair-step design doesn’t hinder usable deck space. There’s still plenty of room for all your tools, personnel and materials. Industry-Leading Deck Size and Capacity Like our EZ Flexx50, the Stair-Stepped Bricking Machine still offers the largest decks in the industry — both in terms of size and capacity. The standard unit has a 4.3-meter (14-foot) long deck and can hold as much as 3,992 kilograms (8,800 pounds). The largest model’s platform is 5.2 meters (17.1 feet) long — larger than any competitive machine — and can hold three pallets of brick totaling 6,000 kilograms (13,200 pounds). The key is high-strength 6061-T6 aircraft-grade aluminum, which is as strong as steel but only two-thirds the weight. With our lightweight, modular design and pin-together construction, the Stair-Step Bricking Machine can be set up in just 60 to 90 minutes, compared to 6 to 8 hours for many competitive models. Ergonomic Bricking The Stair-Stepped Bricking Machine also offers improved ergonomics. By positioning workers and bricks on the stair steps, crews can stage brick at midlevel, minimizing lifting and bending. Additionally, we’re the only manufacturer to include an ergonomic cut-away section in the front arch to allow keying access to close out a ring. Double arches support two rings at once for efficient installation, allowing masons to start installing the next ring while the previous is keyed out. These features allow an experienced crew to install 1 meter (3.3 feet) of brick per hour, compared to roughly .6 meters (2 feet) per hour with other techniques. Efficient Refractory Installation – One Step at a Time The Stair-Stepped Bricking Machine gives you more flexibility for brick management that fits your process while still providing the fast set up, ample deck space and easy keying that Bricking Solutions’ bricking machines are known for. Ready to step up your refractory installation experience? LEARN MORE OR REQUEST PRICING
Bricking Solutions’ Stair-Stepped Bricking Machine Offers Extra Clearance
Bricking Solutions, a full solution provider of refractory installation equipment, introduces the Stair-Stepped Bricking Machine. The new model retains the key benefits of the company’s EZ Flexx50 Bricking Machine, which offers the lightest weight and highest load capacity on the market, but features a stair-stepped deck. This provides enough clearance beneath the scaffolding for forklift access, resulting in more efficient brick delivery. The Stair-Stepped Bricking Machine is available for 4- to 6-meter (13.1- to 19.7-feet) diameter kilns and offers fast set up, ample deck space and easy keying for unparalleled productivity. “For more than 50 years, Bricking Solutions has been providing equipment solutions that are both innovative and customer-driven,” said Heather Harding, Bricking Solutions managing director. “The new model is a next evolution of our bricking machine, offering the best features of our EZ Flexx50 with the stair-stepped deck favored by some masons. It is another example of how our equipment helps customers tailor their refractory installation process for maximum comfort and efficiency.” The Stair-Stepped Bricking Machine offers the industry’s largest capacity and plenty of deck space for brick, personnel and tools. The standard unit has a 4.3-meter (14-foot) long deck and can hold as much as 3,992 kilograms (8,800 pounds). An optional capacity upgrade increases that to 5,987-kilograms (13,200 pounds). The largest model’s platform is 5.2 meters (17.1 feet) long — larger than any competitive machine — and can hold three pallets of brick totaling 4,620 kilograms (10,185 pounds). In addition to industry-leading deck area and capacity, the Stair-Stepped model provides enough clearance to drive support equipment, such as skid steers or forklifts, underneath the machine. This allows crews to easily deposit refractory brick for the bedding crew and bricking machine on the keying side. Some masons prefer this type of brick management since it minimizes brick handling and reduces the need for additional equipment, such as conveyors, to deliver brick. This also improves productivity and reduces brick damage and loss associated with the constant material handling. The 4- to 5-meter (13.1- to 16.4-foot) Stair-Stepped Bricking Machine offers approximately 213 centimeters (84 inches) of clearance. 5- to 6-meter (16.4- to 19.7- foot) models provide approximately 264 centimeters (104 inches). Actual clearance is dependent on machine configuration and kiln size. The Stair-Stepped Bricking Machine also offers improved ergonomics. By positioning workers and bricks on the stair steps, crews can stage brick at midlevel, minimizing lifting and bending. Like all Bricking Solutions equipment, the Stair-Stepped Bricking Machine is simple to assemble and maintain, and provides outstanding safety, productivity and ROI. The machine is manufactured with high-strength 6061-T6 aircraft-grade aluminum, which is as strong as steel but only two-thirds the weight. A modular design and pin-together construction allows for setup in just 60 to 90 minutes, compared to 6 to 8 hours for many competitive models. Bricking Solutions is the only manufacturer to include an ergonomic cut-away section in the front arch to allow keying access to close out a ring. Double arches support two rings at once for efficient installation, allowing masons to start installing the next ring while the previous is keyed out. These features allow an experienced crew to install 3.3 feet (1 meter) of brick per hour, compared to roughly .6 meters per hour with other techniques. For more information on the Stair-Stepped Bricking Machine or other refractory installation equipment, call 1-360-794-1277 or visit the contact page.
Big or Small – Specialized Equipment Maximizes Productivity for Your Kiln
From burn floor to access, every kiln is unique. So, shouldn’t your maintenance solution be, too? Here’s how to select the refractory maintenance equipment — such as kiln access ramps, conveyor systems and bricking machines — that fit your operation and process to maximize your productivity. Access Metal access ramps have the strength and durability to get people and tools safely across the cooler, making them standard in facilities worldwide. Since every burn floor, cooler and kiln is unique, it’s a given that access ramps should be custom designed to ensure a proper fit. The faster your ramp is installed, the faster your crew can get to work. So, to maximize productivity, look for a ramp with a modular design and lightweight components that’s easier to erect with equipment you already have on hand, such as a forklift. A well-designed, lightweight access ramp can be assembled in as little as 1.5 hours in many cases — that’s up to 40% faster than other aftermarket or self-built options. But weight isn’t everything. Ramps must also be durable. Those made with 6061-T6 aircraft grade aluminum provide the best of both worlds — durable, long-lasting results at half the weight of steel. An access ramp manufactured with this material can support as much as 6,804 kilograms (15,000 pounds) live load. That’s as much as a fully loaded forklift. Material Delivery Brick management is another area where the right piece of equipment can maximize your productivity. It’s not always possible to drive into a smaller kiln to deliver brick, making brick management a labor-intensive process. In these situations, conveyors provide an efficiency-enhancing alternative that allows workers to move materials twice as fast and with less physical strain than by hand. With a hydraulic conveyor, a two-person crew can bring a full pallet of brick into the kiln in less than 10 minutes. A roller conveyor would take a crew of five up to three hours to do the same. Look for a unit with modular components to allow for quick setup — as little as one to two hours, depending on the length of the conveyor and site conditions. No matter the size of the kiln — large or small — minimizing brick handling leads to less material damage, increased safety and faster installation. With an incline conveyor, masons can move 15-20 bricks per minute from the kiln floor to the bricking machine with minimal effort. Again, a lightweight, modular design makes transportation and installation easy for a small crew, so look for a machine made with aircraft grade aluminum and easily maneuverable components. Bricking Finally, bricking machines are perhaps the best way to maximize productivity. An experienced crew using a bricking machine can install 1 meter (3.3 feet) of brick per hour, compared to roughly .6 meters (2 feet) with other techniques. However, since kilns come in a variety of diameters, it’s important to find a machine that fits your specific site if you want to optimize these benefits. Bricking Solutions offers a number of bricking machines to fit kilns from 1.2 meters (47 inches) to more than 6 meters (19.7 feet). In addition to correct size, there are other characteristics that will provide greater productivity. A lightweight, modular design means faster setup so you can get to work quicker. A double arch system allows masons to start installing the next ring while the previous is keyed out for more efficiency. Additionally, look for a machine with an ergonomic cut-away keying section. This provides easy access and a clear view of the front arch for key brick installation to close out a ring. Custom Solutions When it comes to maximizing refractory maintenance productivity, partnering with an experienced equipment manufacturer will always provide the best results. Whether it’s an access ramp tailored to your specific site or helping fill in the gaps in your process with specialized clean up tools, our circle of refractory has you covered. Contact our team today to maximize your maintenance productivity. LEARN MORE OR REQUEST PRICING
Bricking Machine Benefits
Get work done up to two times faster with a bricking machine from Bricking Solutions. A pin-together design makes for fast and easy assembly — as fast as 60 minutes. Constructed out of aircraft-grade aluminum, the machine is as strong as steel, but weighs two-thirds less. Each bricking machine provides ample deck space for increased safety and productivity. LEARN MORE ABOUT BRICKING MACHINES OR REQUEST PRICING
Key Considerations for Choosing a Bricking Machine
Not all bricking machines are equal. A thoughtfully designed machine made from quality material can significantly reduce downtime. We created this visual guide to illustrate key considerations.
Playing the Numbers
When to Repair or Replace Your Bricking Machine Equipment investment is always a numbers game. Having the right tools on hand at the right time is imperative for efficient operation. But does it need to be a brand-new machine? Or would repairs to key components provide the same productivity and safety with a smaller investment? And what flexibility does your choice provide? Is there enough in the budget to upgrade to the latest model, or would it be better to use the capital expenditures budget for repairs this year? When it comes to high-quality bricking machines, like our EX Flexx50, durability and longevity can make the repair versus replace decision even harder since, with proper maintenance, these machines can operate safely and efficiently for decades. Eventually, though, it’s a decision that will need to be made. Whether repair or replacement is best for your operation can only be determined on an individual basis, taking into account the condition of your bricking machine and the unique needs of your business. However, here are some key areas to consider as you crunch the numbers. How Old is Your Machine? While a bricking machine from a reputable manufacturer can easily stand the test of time — even in refractory installation’s harsh conditions — age is the first consideration facilities and contractors should evaluate. The number in itself might not tell you if repair or replacement are required, but, like any piece of equipment, there are certain safety inspections that should be conducted based on age and use. Carefully evaluate bricking machines after each use, and initiate an in-depth, on-site inspection from the manufacturer at least every three years or five uses. After eight years of use, inspect bricking machines annually to ensure safety and overall condition of the equipment. These evaluations should include a visual inspection as well as dye penetration tests on all welds. Depending on the model, the technician should also check additional features, such as valves on machines with pneumatic cylinders. As part of our aftersales services, Bricking Solutions offers equipment safety evaluations on-demand, which is highly recommended for older machines. The inspection results will provide a strong basis for objectively evaluating the cost of repairs versus replacement. Other considerations to keep in mind are safety and productivity upgrades that might be available with newer models. Innovative, new technology, such as adjustable dual-arch systems or ergonomic design elements, for example, will increase employee safety and comfort. Upgrading an existing machine with new technology may be considered a repair in some cases, but, at a certain point, replacing an older machine with the latest model will provide a better ROI. Body Damage For models showing their age, or those that fail the dye penetration test, replacement is usually a more cost-effective solution. Whether your rig is made from lightweight, high-strength aluminum or another material, re-welding decreases overall integrity and should be limited. If the dye penetration test uncovers several damaged welds, replacing the machine is the only way to ensure long-term safety. On the other hand, repair is more cost effective for minor body damage, like a bent panel. Here’s where working with a manufacturer really pays off. OEM bricking machines with a modular design allow for easy replacement. Just contact your manufacturer, and a new part is quickly fabricated to your rig’s exact specifications. Installation is a snap, allowing your team to get to work right away. This process requires some lead time but is virtually hassle free compared to reverse engineering a rig designed and built in house. And, by contacting your manufacturer for replacement parts right away, even this hurdle is easily avoided. Safety and Productivity Additionally, refractory installers should consider the overall safety and productivity their bricking machine provides. An unsafe machine should be replaced immediately — full stop. It’s impossible to put a price on workplace safety and cracked or failing welds, XX and YY all put employees in danger. However, if it’s just a single component that’s not working properly, such as a pneumatic arch cylinder, a simple repair is probably all you need to get your machine operational. Like any piece of equipment, bricking machines have parts that need replacing from time to time. Your in-house team can easily complete many of these repairs – if they have the right parts. Stocking common wear parts minimizes unnecessary downtime and keeps shipping costs down. Some equipment manufacturers offer inventory assistance to help you determine which components to keep on hand for your specific unit. Making the Call The decision to repair or replace is not always an easy one, and, ultimately, the answer depends on your specific situation. Thankfully, OEMs like Bricking Solutions offer onsite evaluations to assist in making the replacement decision. To schedule an evaluation or discuss your repair and replacement options, contact our team today! Repair or Replacement Checklist Repair is likely an option if: The machine is less than 8 years old and has been maintained according to manufacturer recommendations. The machine remains structurally strong. Repairs are limited to a single component, like the pneumatic system. Replacement is required if: The machine is 8 years or older and dye test shows failing welds. The machine has cracked wells. The machine would be unsafe even with repairs. New technological advancements offer enhanced efficiency effectively offsetting the additional costs. LEARN MORE ABOUT BRICKING MACHINES OR REQUEST PRICING
Selecting the Right Equipment to Optimize Refractory Safety and Productivity Chris Jones, Bricking Solutions Lead Engineer With refractory maintenance taking place annually in most facilities, making the right equipment choice not only increases productivity, it provides peace of mind in regard to worker safety. Throughout the entire process, from initial inspection to installation and final cleanup, these applications come with inherent dangers. To combat health and safety risks, contractors and facilities rely on specially designed support equipment that can stand up to the harsh conditions of refractory installation. But, just as site-specific evaluations must be made when selecting refractory brick, determining the specific support equipment for optimal results requires careful consideration. To help make the selection process a little easier, here are four things facilities and contractors should consider for long-term safety and productivity. Quality of Construction Materials When it comes to selecting the safest refractory installation equipment, features like fall guards, railings, kick plates, non-slip surfaces and, where appropriate, stainless-steel netting are good indicators of a product’s overall safety contributions. However, contractors and facilities will benefit by looking a little deeper into the construction materials, as well. Products built with high-quality materials will provide long-lasting service even in refractory installation’s harsh conditions. 6061-T6 aircraft aluminum, for example, offers an industry-leading strength-to-weight ratio. It also provides the durability of steel at a third the weight. Incorporated into modular designs, this results in equipment that is lighter and easier to assemble, reducing risk of physical strain. Additionally, the material’s strength can produce a high safety factor when combined with high-quality engineering. When used in safety cages or personnel tunnels, for example, this material is strong enough to protect workers from debris up to 140 kilograms (250 pounds) falling from a height of up to 2.4 meters (8 feet), while still being light enough for two people to maneuver. A custom-engineered kiln access ramp using aircraft aluminum can support as much as 6,804 kilograms (15,000 pounds) live load, increasing protection for workers and equipment moving across the ramp. Tailor-Made Options Customization should also be a key consideration when evaluating refractory installation equipment for safety and productivity. Every kiln and burn floor offers their own set of challenges. Tailor-made equipment means site-specific concerns can be addressed in design, leading to a safer, more efficient solution. For many facilities, this is the main argument for using in-house engineers. However, a number of leading manufactures also understand the importance of customization. Working with these companies can provide the best of both worlds — custom-designed equipment that safely meets the needs of a particular facility backed by the knowledge, experience and know-how of a specialty manufacturer. Support Equipment for the Entire Process Another important consideration for facilities and contractors to keep in mind is refractory installation is a long, multi-phase project. A number of products are available to help improve safety and efficiency throughout the entire process. A thorough investigation of the features and benefits of all available support equipment is the best way to ensure safety and efficiency through the whole process — from inspection to final cleanup. The bricking machine is the most recognizable piece of support equipment for refractory installers. Originally designed to reduce physical strain and safety risks compared to more manual installation methods — like pogo sticks, mechanical jack screws, gluing, and jack and timber — bricking machines have evolved over the years to provide a number of cutting-edge safety benefits. The newest machines offer innovative features, such as adjustable dual-arch systems with pneumatic cylinders to push bricks into place, greatly reducing the risk of injuries from unsupported material overhead. Ergonomic design elements further increase worker comfort and safety. Some models also offer a cut-away section for unobstructed access to the keying area to increase ease and visibility for closing out a ring. However, to truly optimize refractory installation safety, contractors and facilities should consider support equipment beyond just bricking machines. Certain manufacturers specializing in refractory installation have developed entire product lines that increase safety and efficiency throughout the whole process. From safety cages and access ramps to hydraulic and incline conveyor systems that allow workers to move materials twice as fast as manual methods with significantly less physical strain, these manufacturers offer a number of equipment solutions that facilities and contractors should keep in mind. Long-Term Manufacturer Support Regardless of who manufactures a facility’s refractory equipment, ensuring long-term safety requires continual training and maintenance. While the majority of this upkeep falls on the facility or contractor, things like on-site equipment inspections, and parts and service from a reputable manufacturer are worth considering to make lasting safety more attainable. If possible, look to partner with a manufacturer or dealer that offers on-site inspections. These visits can often be turned into learning opportunities for plant personnel and contractors. Over time, crews change, and those on hand for the initial commissioning — where assembly, maintenance and storage requirements were originally outlined — may not be the same faces three years later. Additionally, a lasting relationship with the manufacturer for parts and service support helps ensure equipment is ready for operation during unscheduled kiln downtime. Safety Conscious When it comes to refractory installation safety, making the right equipment choices can lead to long-term success. Partnering with industry-leading manufacturers that specialize in refractory support equipment provides an unparalleled wealth of knowledge and experience, as well as innovations that continue to meet the industry’s evolving safety needs. LEARN MORE OR REQUEST PRICING
Refractory Safety Options That Come Full Circle
With advancements in kiln technology, size and applications, out-dated refractory lining installation techniques — such as pogo sticks or jack and timber — have slowly been replaced in factories and facilities around the world. Bricking materials have not changed much, but how contractors align, place and secure them has become safer and more productive than ever. Throughout the process — from inspection to installation — original equipment manufacturers, like Bricking Solutions, provide specialized tools that contribute to this new level of efficiency. For more than 50 years, we’ve solely focused on manufacturing refractory installation equipment. The result is a full line of specialized equipment to increase workplace safety and efficiency through every stage of kiln maintenance. We call this our Circle of Refractory. Here’s how it works. Safety Cages and Personnel Tunnels Starting with initial inspection, plants have come to rely on safety cages and personnel tunnels to protect workers from falling debris. Not all regions allow workers to enter kilns before coating and clinker is removed, but in areas where this practice is used, facilities that employ cages and tunnels have been able to reduce injuries. Like many pieces of refractory inspection equipment, cages and tunnels appear deceptively simple. However, careful material selection and design are key to optimizing safety. Models manufactured with T6-6061 aircraft aluminum offer the best strength-to-weight ratio. The material is strong enough to protect workers from debris up to 140 kilograms (250 pounds) falling from a height of up to 2.44 meters (96 inches), but can be as much as 50% lighter than comparable steel models. Additional safety features are also incorporated in safety cages from industry-leading manufacturers for even more protection. Crumple zones, for example, absorb the energy of a collapse, preventing serious injury or death. Stainless-steel netting protects workers from falling debris, as well. To increase peace of mind, look to partner with manufacturers that perform a battery of destructive tests to ensure these features perform as intended in an emergency situation. Kiln Access Ramps Custom-engineered kiln access ramps also provide a significant safety benefit for refractory maintenance applications. While a simple plank bridge might have sufficed in the past, today’s refractory installation relies on heavy equipment, such as skid steers and tear-out machines, to expedite the process. To get people and tools safely across the cooler, metal access ramps have become standard in facilities worldwide. Keeping in mind that every burn floor, cooler and kiln is unique, partnering with a manufacturer that provides individualized products will help maximize safety benefits and efficiency for this vital installation component. Again, heavy-duty aluminum equipment provides durable, long-lasting results at half the weight of steel. An access ramp manufactured with this material can support as much as 6,804 kilograms (15,000 pounds) live load. Custom-designed equipment can also incorporate features such as curbs and fall guards, when necessary, to protect workers as equipment moves across the ramp. Conveyors Incline and hydraulic conveyors are tools refractory installers find increases employee safety and efficiency. Parts of the world with access to large labor pools might still find so-called “bucket brigades” a viable option for transferring refractory materials up kiln. However, this method results excess brick handling, which could damage refractory — not to mention a number of unnecessary sprains, strains and repetitive motion. So, with safer options readily available, progressive facilities and contractors are embracing a more automated approach. Using a conveyor, workers can easily move materials twice as fast as manual methods with significantly less physical strain. Additionally, refractory equipment specialists provide lightweight, modular equipment that is easily adapted to fit a specific kiln, including kiln diameter, burn floor length and terrain adjustments. With sections weighing just 16-19 kilograms (35-42 pounds), transportation and installation is easy for a small crew. Bricking Machines While support equipment has played a major role in increasing refractory installation safety, perhaps the most significant gains have been made in the bricking process itself. The widespread adoption of bricking machines in recent decades has revolutionized the speed and overall safety of installation applications. Pogo sticks, mechanical jack screws, gluing and jack and timber techniques are still used by some contractors, but the vast majority of installations worldwide employ a bricking machine. Features and safety benefits vary among bricking machine models, but their overall contributions to installation efficiency are undeniable. Decades-old, first-generation machines can still reduce physical strain and safety risks compared to outdated installation methods — as long as they are well maintained. Newer models provide the most innovative and cutting-edge technology such as adjustable dual-arch systems with pneumatic cylinders to push bricks into place, greatly reducing the risk of injuries from unsupported overhead bricks. Machines featuring ergonomic design elements further increase worker comfort and safety. For example, models from innovative manufacturers, such as Bricking Solutions, offer a cut-away section for unobstructed keying access to increase ease and visibility for closing out a ring. Additional safety features are also available from specialized manufacturers including non-slip decks, dual braking systems and fall guards. An experienced crew using a bricking machine can install 1 meter (3.3 feet) of brick per hour, compared to roughly .6 meters (2 feet) with other techniques. The end result is better refractory installation which increases longevity and decreases downtime and repairs. The widespread use of bricking machines has also contributed to a significant decrease in refractory installation-related injuries and fatalities. And Many More From tear out to clean up, Bricking Solutions offers a full range of support equipment to make refractory installation faster, safer and more efficient. Contact our team today, to see how the tools in our Circle of Refractory can improve your operation. LEARN MORE OR REQUEST PRICING
Bricking Solutions’ After Sales Services Maximize Uptime
Bricking Solutions, a full solution provider of refractory installation equipment, offers a number of after sales services to help operations maintain equipment to maximize uptime during refractory installation applications. Services include equipment evaluation, parts and repair, and refurbishment options. These services, paired with proper routine maintenance, provide a cost-effective measure for facilities and contractors, virtually eliminating unnecessary downtime during refractory installation while ensuring crew safety and extending machine longevity. “Refractory installation jobs are always on a tight deadline since even scheduled downtime carries a hefty price tag,” said Heather Harding, Bricking Solutions managing director. “Bricking Solutions’ equipment is specially designed for the harsh conditions in which refractory installation occurs. Our after sales services ensure equipment is up to the task, keeping the bricking crew on the job until the work is done. Preparedness is key to avoiding unnecessary downtime, so our service team makes sure our customers have the necessary parts on hand through equipment evaluations and parts inventory assistance.” Operations can request on-site equipment inspections for EZ Flexx50 Bricking Machines, older model bricking machines, or other Bricking Solutions original equipment. These one-day evaluations are conducted by experienced Bricking Solutions technicians or trained Bricking Solutions agents for customers outside North America. They include a visual inspection of all welds and structural components as well as complete testing of the pneumatic system to ensure correct operation of all components. A complete report of findings, including recommended repairs and replacements, is provided. In addition to the inspections, Bricking Solutions offers two-day evaluations for customers within the continental U.S. that allow for overnight shipping of parts and installation by the technician, as well as additional employee training on setup, teardown and other key operations as time allows. Equipment inspections and recertification helps facilities and contractors remain compliant with regulations and provides assurance that equipment is safe and ready for operation. In situations where an on-site inspection isn’t feasible, a checklist is provided for in-house inspection, and Bricking Solutions technicians are available to walk operations through questions and parts ordering. Bricking Solutions offers parts inventory assistance to avoid unnecessary downtime and keep shipping costs down. A technician helps operations identify key wear parts for their specific units and advises on an appropriate inventory. Overnight shipping is available on most in-stock parts for orders received by 2 p.m. PST in the case of an emergency. However, keeping an inventory of key parts on hand allows customers to avoid unnecessary downtime for high-demand Bricking Solutions components crucial for machine operation. Some of these require manufactured elements with lead times up to two weeks. “Whether scheduled or unscheduled, having a kiln down for repairs costs facilities hundreds of thousands of dollars a day in lost production,” Harding said. “This time sensitivity is why we developed a robust aftermarket service program to provide solutions before problems arise. Our team will work hard to ensure rapid delivery of parts in an emergency, but it’s always best to be prepared. Planning ahead can also save significantly on shipping costs.” In addition to inspection and parts, Bricking Solutions offers repair and refurbishment services. Evaluation is based on the machine, age and condition. It can include repairs or upgrades to the pneumatic system, frame, arch or deck panels, or safety features. Repairs with stock parts can be done on the jobsite as part of the equipment inspection process. For refurbishments services and any aluminum repairs, Bricking Solutions recommends service be conducted at its Monroe, Washington, headquarters to ensure new parts are properly manufactured to the specs of the original machine. Refurbishment might cost as little as $5,000 or as much as $30,000, depending on the condition of the machine, but can significantly extend longevity and ensure crew safety. LEARN MORE ABOUT AFTER SALES SERVICE OR CONTACT US ABOUT AFTER SALES SERVICE
Keep Bricking Along
Tips to Maximize Bricking Machine Longevity Refractory installation is a demanding application. Thankfully, Bricking Solutions has developed a full line of equipment to make the job easier — and safer — for crews. But harsh kiln environments still take a heavy toll on bricking machines and other equipment.
Bricking Machine Benefits for Improved Kiln Maintenance
Any mason will tell you, the key to effective refractory lining lies in quality brick installation. By minimizing air gaps and interlocking rings or loose bricks, the life of kiln lining is extended, and unscheduled or emergency maintenance can be drastically reduced, saving plants tens of thousands of dollars annually. To achieve high-quality installation as efficiently as possible, more and more refractory contractors are using bricking machines. These machines offer a variety of productivity- and safety-enhancing features over traditional methods.
Port-A-Trac Refractory Transport System Increases Efficiency and Safety
Bricking Solutions, a full solution provider of refractory installation equipment, offers its Port-A-Trac refractory pallet transport system for increased efficiency and safety during refractory installation applications. The Port-A-Trac offers customizable lengths and allows installation crews to transport full pallets of brick into the kiln and under the Bricking Machine easily and with minimal risk to workers, kiln or materials. The system increases material transport efficiency by more than 20%.
Sugar Producer’s Sweet Solution for Annual Maintenance
No matter the industry, annual maintenance can leave a sour taste. Keeping annual inspections and routine maintenance short and sweet is vital for overall efficiency — especially for operations like North America’s largest beet processing factory. So when the plant upgraded to a new 800-ton vertical lime kiln, it decided to look for an upgraded maintenance solution that would increase efficiency and decrease downtime. The sugar producer found sweet success with Bricking Solutions’ EZ Lift Suspended Platform.
Bricking Solutions’ New Rolling Work Platform Offers 25% More Productivity
Bricking Solutions, introduces its Rolling Work Platform for improved safety and efficiency during maintenance of horizontal vessels. The platform offers 25% increased productivity over traditional rolling scaffolds and features a durable, custom-engineered design. It is used in a variety of applications including water treatment, tunneling and mining.
The Benefits of Aluminum on Your Bottom Line
Kiln maintenance can take its toll on your bottom line. Plant managers need reliable, efficient maintenance methods to get back up and running quickly and minimize profit-stealing downtime. That requires using the right equipment — made from the best materials.
Reinforce Safety with Hydraulic and Incline Conveyors
Bricking Solutions, a full solutions provider in kiln refractory installation equipment, offers Hydraulic and Incline Conveyors to increase maintenance efficiency and reduce worker physical strain. Made from heavy-duty aluminum, these conveyors increase efficiency and safety, while minimizing damage to kilns and refractory materials during routine refractory maintenance.
Radialign Laser Alignment Device For Precise Refractory Alignment
Bricking Solutions, a full solution provider of refractory installation equipment, offers the Radialign Laser Alignment Device, which increases radial alignment accuracy during refractory install for longer brick life, minimized downtime and reduced mechanical stress on the kiln. The Radialign is part of Bricking Solutions’ full-service product offerings for refractory maintenance.
OEM Kiln Access Ramps: Why Partner with a Pro
OEM Kiln Access Ramps: Why Partner with a Pro Kiln access ramps are an important part of safe, efficient kiln maintenance. Producing one in-house may seem cost efficient but poor design and lengthy installation often end up costing more in the long run. Partnering with a specialized manufacturer offers added benefits such as a custom engineered design, easy installation and service options that result in a better return on investment.
Increase Worker Safety with Inspection Cages
Lightweight Safety Solutions Kiln repair and maintenance are undoubtedly hazardous tasks, but kiln operators can take steps to provide additional protection for workers. Safety Inspection Cages provide heightened protection keeping them out of harm’s way from debris that commonly falls as coatings shrink and expand. These cages are lightweight, easy to operate and conveniently pair with our Personal Protection Tunnels.
Kiln Access Ramps Offer 40 Percent Faster Installation Time
Bricking Solutions, a full solutions provider in kiln refractory installation equipment, introduces Kiln Access Ramps to provide safe and easy access for maintenance personnel and equipment.
Lightweight, High Capacity Bricking Machines
Bricking Solutions, a full solution provider of refractory installation equipment, offers the Ez Flexx50 Bricking Machine. The largest version weighs 3,100 pounds (1,406 kilograms), making it one of the lightest
Revolutionizing Refractory, Brick by Brick
More than 50 years in the business has taught us what it takes to be industry leaders. We put the best of that knowledge into our Ez Flexx50 Bricking Machine, the lightest, strongest and safest refractory installation
Universal Safety Inspection Cage
Introducing the NEW Universal Safety Inspection Cage. Here at Bricking Solutions, we took our 16 years experience of engineering and manufacturing Safety Inspection Cages and incorporated the latest safety and design concepts to create a Safety Inspection Cage that is still the safest in the industry, but only weighs 64 kg!
Access is the First Consideration in Kiln Maintenance
Each burn floor is unique and every configuration is different. Here at Bricking Solutions, we understand that and have built 200 Custom Kiln Access Ramps to plants all over the world.
Small Size, Big Solution
Do you have a kiln 4M (13′) or smaller? Bricking Solutions has the right size bricking machine for your kilns from 4M all the way down to 1.5M. Our newest addition to our Bricking Machine line
Bricking Solutions Bricking Machine vs the Competition
BRICKING SOLUTIONS: Ergonomic Cut-out section in front arch – Allows key mason room and keying access to close out row. Load Capacity: Standard 4000kg (8000 lb): 2 pallets of brick plus workers and tools Optional 6000kg (13228 lb): 3 pallets of brick plus workers and tools Optional small kiln 2722kg (6000 lb):1 pallet of brick plus workers and tools
Taking You to New Heights
Did you know that Bricking Solutions builds platforms for Isamelt Furnaces? Here is our recent order to Kansanshi Mining which includes a custom Ez Lift Suspended Platform built for 3 different sizes. Suspended by a trolley that spans the length of beams enables the platform to move into a different sections of furnace.
The World Leader in Refractory Maintenance Products
We are the world leader in Refractory Maintenance Products and we have been manufacturing equipment for cement kilns since 1967.
Introducing our Newest Bricking Machine – The Ez Flexx50 – Lightest Machine In the Industry
It is with much pride that Bricking Solutions introduces their newest bricking machine, the EZFlexx50.
Hydraulic Conveyor for Material Handling
Bricking Solutions makes a wide variety of products for Refractory Maintenance. It is all we do. One product that we have been manufacturing for 15 years is our Hydraulic Conveyor System. The Conveyor System not only brings refractory into the kiln when fork truck access is limited but can also be used for removing debris out of the kiln or even the cooler to help with mucking out. The Conveyor System comes in 3 widths and a variety of lengths; 304.8mm (12”) with max length of 85M (280 FT), 508mm (20”) with a max length of 76M (250 FT), 762mm (30” ) with a max length of 45M (150 FT). Our hydraulic conveyor systems has a maximum capacity of 2000lb/907kg over the full length of the conveyor and a speed of 45M per minute. Our conveyor systems have a drive section where the hydraulic power is connected to and a tail section with a drum roller allowing the conveyor belt to return to the end, these two sections have a combined length of 10’/3m. The sections between the drive and tail are called extension section which are 10’/3m long giving the hydraulic conveyor the ability (depending on the length you have requested) to adjust from 20’/6m to a maximum of 250’/76m. The conveyors connect very easily with two workers bringing each section together and adjusting the legs to desired height. They have forward and reverse gears so they don’t have to be taken apart to reverse the direction of the conveyors movement and they have variable speed control for efficient brick management coming into the kiln. LEARN MORE OR REQUEST PRICING
Ez Lift Suspended Platform
We have designed and tested and re-designed for a new and improved Suspended Platform. Bricking Solutions has been manufacturing refractory maintenance products for over 40 years and the Suspended Platform is the Safest, most Effective work access in vertical vessels.
Successful Bricking Solutions Training
We had a successful training at Bricking Solutions. Visitors from Holcim Trident – MT, Ash Grove Cement Leamington – UT, and Argos Cement Calera – AL were present. We went over replacing and trouble shooting parts on both our old MOR and our new Ez Flexx Bricking Machine as well as the new machines safety features and benefit.
Ultratech Rawan Kiln 2 Successful commissioning of their Kiln Access Ramp
Ultratech Cement Ltd, Rawan Plant, 10,000 tpd KHD Kiln 2 – Successfully commissioned their new Kiln Access Ramp.
We are the Industry Leader in Safety Inspection Cages
Bricking Solutions has been manufacturing Safety Inspection Cages and Personal Protection Tunnels for 15 years. We rigorously test all our cage designs and they meet industry safety standards.
Maintenance Solution for Cement Plant Preheat Tower Vessels
Maintenance work in preheat tower vessels (cyclones, risers and pre-calcinator) is not only difficult and time consuming but can be a dangerous task.
Bricking Solutions Custom Bedding Cart
The Bedding Cart not only allows for the movement of bedding refractory as the bedding process progresses, but provides stair steps to facilitate the placement of refractory to or just above the spring line on larger kilns. Congratulations to Ultratech Cement – Kotputli Works for their new Custom Bedding Cart.
J.T. Thorpe & Son, Inc receive an Econ-O-Ring and 200′ Long Hydraulic Conveyor
Thank you J.T. Thorpe & Son, Inc for your order of the Econ-O-Ring Bricking Machine and the 12″ wide by 200′ long Hydraulic Conveyor system.
Torpedo Ladle Bricking Machine
Did you know we also manufacture custom brick lining machines for torpedo ladles? Our most recent custom machine was for Zapadno Sibirskiy Metallurgical Combinat – West Siberian Steel Works (ZSMK) Russia.
Shurovsky Cement, Holcim Russia, receives new Mini Econ-O-Ring Bricking Machine
Thank you and congratulations to Shurovsky Cement, Holcim Russia in the Moscow Region and Hoganas AB Bjuf for their order of a new Mini Econ-O-Ring (MECOR)
Fork Truck Bracket
http://www.youtube.com/watch?feature=player_embedded&v=hUqoyzD8tME Utilizing a fork truck, you can easily transport a completed arch or set of machine frames in and out of kiln The use of a fork truck bracket enables the arch and frames to be moved without being disassembled, saving time during each use With arch turned parallel to fork truck and kiln, and bracket fully engaged on forks, front of arch leads fork lift wheels by approximately 10 feet (304.8cm) Safety Features designed into both standard and optional dual functionality Fork Truck Brackets include chains and hooks to secure arch to bracket, fork lift locks to secure bracket to forks, and locking pin to keep bracket in position. Dual Functionality Bracket designed to move bricking machine into the next refractory zone in the kiln.
Brick Lining Equipment for Ambuja Cement – Rabriyawas Works
Thank you and congratulations to Ambuja Cement Limited – Rabriyawas Works for their order of a Premium Ez Flexx EOR Bricking Machine, Kiln Laser Target and Burner Alignment, and Fork Truck Bracket. Thank you also to The Consultants for your hard work!
Custom Ramp Tunnel Cage System for Titan Cement
Thank you and congratulations to Titan Cement Company Greece for their new Ramp Tunnel Cage System and Refraconsulting for your hard work.
Proper refractory staging for efficient and safe refractory installation
The number one reason for slow bricking times is slow supply of brick to the masons. Every plant has different obstacles such as: limited access, small burn floor, small kiln diameter, or the location of the job. Replacement of brick could be down in the cooler or way up in the intake section of the kiln. These are only a few of the many different examples of difficult supply demands. Whether you own our EZ FLEXX bricking machine, our old classic MOR or an off brand bricking rig we can help you make the use of your bricking machine more efficient with many material handling options.
Refractory Installation Equipment Care
The following is an excerpt from Stacey Rice, BBS Service manager, and her response to our agent’s service report and follow up request on how their customer can reduce maintenance costs
Kiln Access Ramp for TXI Hunter Cement
Congratulations TXI Hunter Cement – Texas, USA and Thank You to Southern Refractories – Texas, USA for their order of a new Kiln Access Ramp.
Turkish cement industry continues to grow even though to the global economic crises.
The clinker capacity exceeded 64 million ton and cement capacity exceeded 105 million ton in Turkey with 48 integrated plants and 20 grinding stations as of 2010. If we consider the figures of 2009, Turkey is the biggest cement producer in Europe and the 5th in the world.
Re-joining with Tianjin Pfister
Bricking Solutions and Tianjin Pfister have re-joined forces. Tianjin Pfister has been appointed exclusive distributor for Bricking Solutions for China.
Double the Productivity
Bricking Solutions announces twin bricking machines capable of bricking from 3.8m kiln ID to 6m kiln ID. These talented machines not only adjust from 3.8m kiln ID to 6m kiln ID, but are able to adjust easily in the kiln on the fly to make bricking though tapers and conical sections a breeze.
Largest Machine Ever
Bricking Solutions is delivering the largest fully adjustable EZ FLEXX bricking machine ever built to LKAB mining located in Kiruna, Sweden. This machine will have a range of 5.5m to 7.5m to work in their two 5.5-6.1m kilns, their 6.7m kiln and their 6.8-7.5m kiln, with the ability to adjust through the conical sections on the fly taking only minutes for each adjustment.
Bricking Solutions knows that efficient handling of refractory can make or break a relining project. The Bedding Cart not only allows for the movement of bedding refractory as the bedding process progresses, but provides stair steps to facilitate the placement of refractory to or just above the spring line on larger kilns.
Bolt together Bricking Rig for a furnace with limited access
It is always gratifying to receive a message like the one below. Bricking Solutions lived up to its name by solving a limited access issue (48” man access port) along with the challenge of furnishing a large adjustable machine for multiple diameter (16” and 19” Brick I D), multi brick layer cylindrical furnace in a Sulfuric Acid Generation Process.