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
Work from the Bottom Up – Bedding Cart
Speed up bedding out larger kilns while providing a safe, ergonomic working deck with stair steps for higher brick placement. The Bedding Cart is a portable aluminum rolling deck with ergonomic steps to allow masons to bed the bottom of the kiln up to the spring line with ease.
Here at Bricking Solutions, we welcome you to take a look at our latest catalog. The latest version features all our different models of bricking machines and important specifications. There are also some products you may not be familiar with. Have a look! High Quality Download Web Optimized Download
Our NEW 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!
Is Your Brick Lining Machine The Safest In The Industry
Safety has been our focus here at Bricking Solutions since we started building Brick Lining Machines in 1967. For over 50 Years, Bricking Solutions has been designing and building the industry’s SAFEST brick lining machines.
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
Evaluations – Keeping Your Equipment Outage Ready
It’s there, in the shadow of your kiln, waiting to be called upon to perform its one task – helping you quickly and safely reline your kiln. But, your Bricking Machine has been worked hard over the years and is a little beat up.
Without a Bridge Your Kiln is an Island
The scene is familiar. Your crew steps onto the burn floor in preparation for kiln maintenance. The door is opened. The kiln is cooling down. The outage clock begins to tick.
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
Bricking Solutions Arch Runaway Test
Whenever we manufacture a new design of one of our products, we put it to the test and come up with real, worst case scenarios that could happen. Here is a video of a runaway arch on a bricking machine. The test was very successful as you can see. Click here to watch the Video
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.
Work Smarter, Not Harder
Work Smarter, Not Harder Today, working harder is not enough. Successful cement operations are more about finding new, efficient ways of doing the work in order to increase profits and outsmart the competition. You know that all too well.
The World Leader in Refractory Maintenance Products – It’s all we do.
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.
Suspended Platform discounted and ready for shipping!
Bricking Solutions Ez Lift Suspended Platform has been used once, refurbished and is ready for shipping. The platform has a diameter of 19.6″ / 6M and includes inner and outer fall guards.
20″ (508MM) Wide Hydaulic conveyor ready to ship for early December ocean delivery!
Are you going into an outage soon? Do you need a quick and easy way to transfer bricks into your kiln? We have a 20″ (508mm) wide hydraulic conveyor that is ready to ship.
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.
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.
ThorLinings – Bricking Solutions Agent
Initially as a refractory installation company ThorLinings is also refractory supplier of the materials and new refractory installation technologies. The company is a continuation of their founders long experience in the refractory material supplies and refractory installation services. From the very beginning ThorLinings company has been developing the concept of SUPPLY & INSTALL.
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.
Bricking Machine and Conveyors for VALE Oman Pelletizing Company
Successful Commissioning of Bricking Machine and Conveyors report for VALE Oman Pelletizing Company by MERTEC Middle East LLC.
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.
100′ / 30M Personal Protection Tunnel for Nuh Cimento Sanayi A.S. Turkey
Thank You and Congratulations to Nuh Cimento Sanayi A.S. and Somer International – Turkey for their purchase of a 100′ / 30M long Personal Protection Tunnel.
USA Bricking Machine Evaluations
JULY SPECIAL This month we are offering a special for a Level 2 Bricking Machine evaluation. For every evaluation we will give a 10% discount on all parts used to fix your machine to manufacturers specs.
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.
Ramp Tunnel Cage System for Holcim El Salvador
The Ramp Tunnel Cage System is designed so that workers are protected from falling debris while Brokk demolition is taking place just inside the kiln. Thank you and Congratulations to Holcim El Salvador.
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.
New Steel Fittings
Due to a change in the manufacturers’ process to reduce material in the fittings for cylinders and master valves we will be changing our fitting supplier. The new fittings will be steel and have a better collar for applying pressure to take out hose, a better swivel feature and a rubber washer instead of a metal washer.
New 508mm (20″) wide Hydraulic Conveyor for Cementos Yura, Peru
Bricking Solutions has been manufacturing hydraulic conveyors for over 10 years. These conveyors are great for transporting new refractory in and removing old refractory out. They are a perfect solution for limited access kiln when a fork lift is not able to go into the kiln.
Thank You and Congratulations to Shree Cement for the purchase of the Premium EZ Flexx Bricking Machine.
Shree Cement of India, with the help of NV Techno Services Pvt Ltd, has purchased a new Premium Ez Flex Brick Lining Machine, Radialign Laser and a 20′ Steel Storage Container.
New Ramp and Load Fixture to Cement LLC Slantcy, Russia
Thank You and Congratulations to Cement LLC Slantcy Russia and Hoganas. Cement LLC purchased a new Kiln Access Ramp, Load Fixture loading device, Brokk outrigger support matting for the ramp and a Muck-it-Bucket.
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.
Bricking Solutions Port-A-Trac Delivery System for material handling within two 3.5m x 60m Acid Bake Kilns
CASE STUDY: Equipment: Port-A-Trac Description: The Port-a-Trac is a light-weight, aluminum, modular system for transporting full pallets of brick into small kilns where forklift access is limited. Location: Lynas Advanced Minerals Plant, Gebeng, Malaysia
Arabian Yemen Cement receives new custom Kiln Access Ramp
Arabian Yemen Cement Company Ltd received a new custom Kiln Access Ramp from Bricking Solutions. Congratulations on their order and thank you to Mertec Switzerland!
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.
Cement LLC’s new Ramp and Load Fixture in Russia
Cement LLC in the Leningradskaya region of Russia became the fourth Russian Cement plant to upgrade to a 6061 T6 high strength aluminum kiln access ramp system for safe and efficient kiln access, while also becoming the first Russian plant to take advantage of the unique Bricking Solutions load fixture design for installation and removing the bridges section.
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)
Personnel Protection Tunnel System and Safety Inspection Cage for Cimsa Cimento Sanayii – Kayseri and Mersin Plant
Bricking Solutions Personnel Protection Tunnel System provides a safe environment for workers from falling coating and brick inside your kiln.
Kiln Access Ramp for Lafarge Algeria – Ciment Blanc Algerien
Access into your kiln is one of the most crucial aspects of an outage. Having the right solution to bridge that gap is also very important. Bricking Solutions has been designing and manufacturing Kiln Access Ramps for over 20 years!
New Safety Inspection Cages to ACC Limited Madukkarai and Chanda Works
Thanks you and Congratulations to ACC Limited Madukkarai Cement Works for their order of a new 2 Man Heavy Duty Inspection Cage and Chanda Cement Works for their order of two 4 Man Heavy Duty Inspection Cage. Thank you Indrex Pvt Ltd / The Consultants for all your hard work!
Premium EZ Flexx FDEOR Bricking Machine for Veolia Environmental Services Australia
Thank you and Congratulations to Veolia Environmental Services Australia for their new purchase of Bricking Solutions Premium EZ Flexx full range Bricking Machine, Radialign Laser and Fork Truck Bracket. Thank you Brokk Australia for your hard work!
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!
Premium Ez Flexx EOR Bricking Machine for Zona Franca Argos Colombia
Thank you and Congratulations to Zona Franca Argos S.A. Colombia for their order of a new Premium Ez Flexx EOR Bricking Machine designed for a range of 4M – 5.25M – Thank you Remapril – Oficina Técnica Regional for your hard work!
Brazilian Cement Market – By Bill Barraugh, President of Bricking Solutions
I just returned from a visit to Brazil with the purpose of updating or reviewing our efforts to break into the Brazilian Cement market with Bricking Solutions services and products. I found that the Brazilian market has many similarities and some differences to other country’s Cement markets.
The Mechanical Elephant in the Plant
With the economic downturn, the question cement plants are asking is: “How can costs be cut whilst still maintaining or improving efficiency?” The number one factor in achieving these goals is what can be done with current equipment. When internal kiln maintenance equipment is under the microscope, sometimes it is just as easy as having a machine inspected or audited.
Kiln Access Ramp and Ez Flexx Bricking Machine for Martin Marietta Specialties
Thank you and congratulations to York Lining International and Martin Marietta Specialties for their package order.
Proper refractory staging for efficient and safe refractory installation through safe and effective material handling
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.
2 Man Safety Inspection Cage for Adocim Cimento
Congratulations to Adocim Cimento Beton Sanayi Ve Ticaret and Thank You to Somer International for a new 2 Man Safety Inspection Cage custom designed for a 4.15M and a 4.4M kiln.
Refractory Installation Equipment Care
The following is an excerpt from our BBS Service manager, Stacey Rice, response to our agent’s service report and follow up request on how their customer can reduce maintenance costs
Cemax Engineering Conference
Bricking Solutions was invited for a symposium in Malaysia by Jimmy Ooi and JL Ching of Cemax Engineering which was held in Kula Lumpur June 27th – 29th 2012. They had over twenty in attendance from cement plants from around Malaysia, there was very good participation from the invited guest with questions and comments.
Basic EZ Flexx for CMS Clinker
Congratulations to CMS Clinker Sdn Bhd and Thank You to Cemax Engineering Sdn Bhd and Brokk Asia-Pacific Pte. Ltd for their new Basic EZ Flexx Bricking Solutions bricking machine
Ramp and Bricking Machine Evaluation Program
Still going the through the doldrums of low cement demand that most plants in the North America market are experiencing! Well, now is the time to take advantage of the time on your hands and be proactive for the next upswing in cement demand by making sure your refractory installation equipment is safe and ready to use.
Basic EZ Flexx Bricking Machine for Hail Cement Company
A special thanks to Chengdu Design and Research Institute (CDI) for ordering our Basic EZ Flexx Bricking Machine for Hail Cement Company in Saudi Arabia.
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.
Premium Ez Flexx Bricking Machine for Northern Region Cement
A big thank you to China national Building Material (CNBM) for ordering our Premium Ez Flexx Bricking Machine for Northern Region Cement in Saudi Arabia.
Brick Management with a Port-A-Trac
This innovative brick transfer system is a supportive component adding efficiency, less worker fatigue, and improved brick management to the modern pneumatic bricking machine. This smaller supportive component was designed a decade ago with the sole purpose of feeding brick to bedding and mason crews while utilizing only a maximum of two workers so brick management didn’t interfere with brick installation.
Radialign Laser Alignment Device
The purchase of a laser can be justified simply by the cost of lost brick due to improper radial alignment Lost brick also adds up to premature shutdown of the kiln and thousands of dollars in lost production The laser can be used to mark a large section of the kiln in about an hour The laser will precisely locate retaining rings and other high cost specialty refractory products The laser will give the kiln maintenance supervisor instant feedback and quality control The laser ensures that the bricking crew or bricking contractor has maintained proper radial alignment
New 40mm Cylinders
Why the need for this change?Since many of our customers have air quality and air volume issues we have decided to change to 40mm cylinders. These new cylinders will not only have the same hole spacing for installation as the 30mm cylinders but the new shafts will fit in either the new 40mm cylinders or the old 30mm cylinders so there is no need for us to carry more inventory.
PPT Trinidad Cement 11/07/2011 Case study
“Within 24hrs I was inside the kiln. I installed the safety cages first. The safety cages are wide enough for me to plank off with 3/4″ ply board. I then installed the rig. The frame was just rolled in on the ply board and the rig was set up as normal. A good work crew of 8-10men was used on this job and within 3 hrs we were able to assemble everything” – Alonzo Ramsaran Kiln Engineer
Kiln Bedding Cart
Tired of using spring boards or crates to install your refractory to spring line or in reality as high as gravity will allow when bedding your kiln? Take a look at a 21st century solution a custom bedding cart.
Bricking Solutions and her employees are proud parents of 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.
Lubricator Filter System
Bricking Solutions now has a protective cover for our lubricator filter system, this new cover will come standard on all new premium bricking machines. It will also be available as a retrofit for all machines in the field.
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.
Pass Thru Trolley
The Pass Thru Trolley allows a full pallet of refractory / brick to be placed onto the bricking rig from the down kiln end by a forklift, and then the pallet can be moved under the arch to the up kiln end where it can be easily accessed.
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.