2025 Brictec Iraq Clay Sintered Brick KTB Project

Construction Process of Clay Brick Plant

I. Project Overview

The construction of a clay sintered brick plant is a systematic project consisting of several key sections: raw material yard, forming workshop, drying system, tunnel kiln firing system, finished brick packaging line, and supporting utilities.
The entire process follows the principles of scientific planning, phased construction, quality first, and safety control, ensuring stable operation after commissioning.

Our product pricing is customized according to your production capacity requirements and detailed project drawings, ensuring the most cost-effective solution for your brick plant.

II. General Construction Workflow

1. Survey and Design Phase

(1) Geological investigation and foundation bearing tests;

(2) Plant layout and functional zoning design;

(3) Determination of tunnel kiln orientation and foundation layout;

(4) Completion of civil, structural, and equipment design drawings.

2. Civil Foundation Construction

(1) Site leveling and road hardening;

(2) Excavation and concrete pouring;
(3) Installation of embedded parts and kiln foundation;
(4) Application of moisture-proof layers.

3. Equipment Installation and Commissioning

(1) Installation of raw material line, brick forming units, and stacking robots;
(2) Installation of drying ducts, fans, and hot air systems;

(3) Tunnel kiln masonry and burner system setup;
(4) PLC automation and sensor calibration;
(5) Unloading and packaging systems commissioning.

4. Trial Production and Validation
(1) No-load testing → Kiln drying → Pilot firing;

(2) Optimization of firing curves and temperature zones;

(3) Verification of water absorption, compressive strength, and surface quality.

III. Tunnel Kiln Construction Process (Key Section)

The tunnel kiln is the core unit of brick firing, and its construction quality directly determines production efficiency and product performance.

1. Kiln Foundation

(1) Bearing capacity ≥ 180kPa; flat and crack-free concrete base (≥ C30 grade);
(2) Reinforced with a waterproof insulation layer;

(3) Track elevation error ≤ 3mm.

2. Kiln Body Masonry

(1) Multi-layer composite structure using high-alumina bricks and insulation materials;

(2) Vault-type roof with steel frame support;

(3) Floor bricks made of wear-resistant materials with smooth leveling;

(4) Mortar joints ≤ 3mm, bonded with high-temperature adhesives.

3. Combustion & Ventilation System

(1) Equipped with burners, air ducts, and exhaust fans;

(2) Controlled via PLC with temperature zone sensors;

(3) Sealed ducting prevents backflow and gas leakage.

4. Kiln Car and Track System

(1) Kiln cars made of heat-resistant steel;

(2) Flatness tolerance ≤ 2mm;

(3) Tracks aligned precisely for stable operation.

5. Kiln Drying and Trial Operation

(1) Temperature rise ≤ 20°C/h in stages;

(2) Full drying cycle: 10-15 days;

(3) Continuous monitoring of stress and temperature distribution;

(4) Trial firing follows successful drying.

IV. Quality Control Key Points

V. Acceptance and Optimization

1. Full inspection of kiln geometry, sealing, and control systems;

2. Submission of construction and inspection records;

3. Monitoring of energy consumption and product quality during test run;

4. Continuous optimization of firing parameters for best efficiency.

● Company profile

Xi'an Brictec engineering Co., Ltd. (abbreviation: Xi'an Brictec) was founded in 2011. It employs senior Italian engineers to work with domestic experts, creating a strong technical team by combing the European and Chinese technologies. The company is devoted to provide clients multiple professional brick making solutions, including building structure bricks, decorative bricks,wall cladding bricks, paver and dry press bricks, etc.

Business Scope

(1) Design and engineering
Xi’an Brictec offers process design and engineering service for clients to have a fully automated modern bricks and tile factory, including chamber drying, tunnel drying, rapid drying and tunnel kiln and other process design and technical consultation, among which the dryer and kiln constructing and engineering is the utmost importance in our general contracting program. This part is the key to achieve production targets by using key technologies in the project.

(2) Machinery manufacturing and supply
Xi’an Brictec Machinery Equipment Manufacturing Co., Ltd. introduces the latest European brick machinery technology for smooth production domestically. In 2018, Xi’an Brictec built cooperation relationship with Shandong Mine Machinery Cosmec Materials Machinery Co, Ltd, jointly R &D and manufacturing automation equipment for brick making.
1.Cutting machine, setting machine, automatic unloading and packing machine and automatic packaging machine;
2.Ferry car, cone blower, stepping machine, pulling machine, kiln car and other kiln automation equipment;
3.Gas burning system (natural gas/liquefied petroleum gas / coal gas), liquid burning system (heavy oil/waste tire oil), solid fuel burning system (pulverized coal, petroleum coke, rice husk, palm kernel husk, coconut husk, cottonseed husk, etc.)

(3) Installation, maintenance and production guarantee service
Xi’an Brictec provides production, commissioning and maintenance services to brick making factories, helping clients to make bricks easily.

● Project reference from Xi’an Brictec

1.Shaoxing Lvzhan environmental protection technology Co., Ltd

Xi’an Brictec designed this Lvzhan project in 2023. The project has annual output of 300,000㎡ of sintered bricks and prefabricated brick wall by using local solid waste such as chemical contaminated soil, construction residue, printing and dyeing sludge as the main raw materials, etc. so as to make high quality sintered bricks making, and 60%-70% of electricity needed for production line is from the photovoltaic power generation on the factory roof. Xi’an Brictec provides whole package service from the preliminary planning and design of the project to the supply of core equipment in the later stage. Single layer tunnel dryer process is adopted with natural gas burning system for tunnel kiln (7 meters inner width). Xi’an Brictec has delivered a very satisfactory EPC project to our client, and also set a new benchmark for the solid waste recycle and utilization in the industry.

2.Najmadin project in Iraq

This project was jointly designed and implemented by Xi’an Brictec and China National Building Materials Co., Ltd. in 2023, with a daily output of 750 tons of sintered bricks. It is located in Sulaimani Province, Kurdish region of Iraq, and the raw material is shale. Xi’an Brictec has participated in project planning, design, construction and commissioning. Single layer tunnel dryer process is adopted, and Heavy oil/liquefied petroleum gas dual fuel serve as the fuel for dryer and tunnel kiln (9 meters cross-section) . In this project, Xi’an Brictec competes with European production line on the same platform and wins honor for the country. So far the project has been put into production, expecting to meet the production target in May 2024.

3.Antique Bricks Project for Yan'an Green Building Material Recycling Industrial Zone

The project was designed and implemented by Xi’an Brictec as a whole in 2022, mainly to produce antique bricks, facing bricks and paver, etc.. The raw material is high-quality shale and purple sand soil, and the fuel is natural gas. The entire production line combines two shaping methods (extruding and pressing), and uses chamber dryer for drying and tunnel kiln for burning, and integrates three shuttle kilns for antique bricks production. Xi’an Brictec was fully engaged and offer excellent package service in the project in the preliminary process design, dryer construction and core equipment supply and production commissioning. This automatic degree applied in this project is the highest domestically, also meets the advanced international level.

4.Guangdong Baolihua Electric Power Co. Ltd. brick making project with high content fly ash as raw material

Xi’an Brictec designed the whole project and led multiple raw material batching experiments, and finally got the result of 65% fly ash content being the perfect ratio to produce qualified sintered bricks. And because of this project, Xi’an Brictec has obtained the invention patent for making bricks with high content fly ash added.

5.ECO CERMICS project in Bangladesh
This is an EPC project by Xi’an Brictec. Single-layer tunnel drying process is adopted with two 4.8-meter tunnel kilns in use. Bongianni soft plastic extruder from Italy, roller and pulverized coal burner invented by Xi’an Brictec are also applied in this project. Invested by GPH, the 3rd largest cement enterprise in Bangladesh, the production line has the characteristics of highest automation and largest production scale. The factory roof is laid with solar photovoltaic, offering 60% power generation for production line.

6.Uzbekistan Project

The project is for the high-grade brick making production, ranking top three in Uzbekistan. It has two production lines and Xi’an Brictec is responsible for the whole set of cutting, loading & unloading automation system and the natural gas burning system. Client thinks highly of Xi’an Brictec and compliments it as the most reliable partner, offering the easier natural gas burning system with lower energy consumption than European burning system. With the assistance of Xi 'an Brictec, the client uses tire pyrolysis oil to make bricks in its Phase II project, producing high quality bricks under low cost.
Xi 'an Brictec will continue to make breakthrough in every aspects, continuously providing all various tailor-made brick making solutions for our valuable clients!

● Business region

Over 30 countries and regions including China, Russia, Kosovo, Kazakhstan, Uzbekistan, Tajikistan, Vietnam, Malaysia, Iraq, India, Bangladesh, South Africa, Zimbabwe, Peru, Colombia...
In addition, the company has local offices and after-sales service centers in countries such as Iraq, Kazakhstan, Bangladesh, Uzbekistan, Zimbabwe and other.
Adhering to company’s culture and spirit “ Struggle-oriented and customer-centered”, Xi’an Brictec is here to help you make bricks easily!