Firebrick Forming
Brick forming has been used to hold heat inside any given building since the early twentieth century. However, since that time, the process of making bricks to withstand extreme temperatures has changed significantly. At the turn of the century, most bricks were made with ordinary clay, which did not provide much fire resistance. However, modern firebrick forming is quite different.
Today, firebrick forming uses high-temperature refractory material, which is typically composed of clay, alumina silicate, magnesia, and other mineral components. This material is specifically designed to withstand temperatures of up to over 2,500 degrees Fahrenheit. When fired in a kiln, the brick takes on a vitrified, or hardened, state that is extremely resistant to fire and heat.
The process of firebrick forming begins with a sample of the refractory material, which is then poured into a mold. This mold is designed to the exact shape, thickness, and composition of the desired brick. The mold is then loaded onto a roller and compressed, pushing the raw material into the desired shape. Depending on the desired result, different molds may be used. For example, insulation bricks usually require a lower- temperatures to form and a thinner, more porous mold.
The second step of the firebrick forming process is to dry the raw material. During this process, moisture is removed from the material through a combination of air drying and heat, ensuring the brick is ready for the firing process. After drying, the material is then loaded into a kiln, where it is heated to the exact temperature required to form the desired brick shape. Depending on the type of brick, the firing process may take anywhere from 15 minutes to 12 hours.
Once the brick is fired, it is then cooled to room temperature, usually by an air-cooled system. This is necessary to ensure the brick has fully “set” and prevents any external damage to the brick. After cooling, the brick can then be inspected for quality and any imperfections before being used in the building process.
Overall, the process of creating firebricks is extremely complex and requires a great deal of experience. The key is to ensure the exact composition and temperature necessary for the desired result. If not done correctly, the result may not be sufficient to provide the desired protection against fire and heat. Fortunately, modern advancements in firebrick forming technology have made it easier for experienced masons and builders to create strong, reliable firebricks.
