Data-Backed: 7 Proven Ways to Extend the Lifespan of a Brick Machine

Fév 2, 2026

Résumé

An inquiry into the operational longevity of industrial machinery, specifically the brick making machine, reveals a complex interplay between mechanical design, operational conduct, and maintenance culture. This analysis examines the determinants of a brick machine's functional lifespan, which typically ranges from eight to fifteen years but can be significantly extended. The investigation moves beyond a mere catalogue of parts to a deeper exploration of the foundational principles governing its function, including the physics of compaction and the tribological effects of raw materials. It posits that longevity is not an inherent, fixed property of the machine but rather a variable outcome contingent upon a structured regimen of care. The discourse outlines seven distinct, yet interconnected, domains of practice essential for maximizing this lifespan: foundational knowledge of the machine's mechanics, rigorous maintenance protocols, skilled operator conduct, mitigation of environmental and electrical adversities, strategic management of components, periodic modernization, and the implementation of data-driven analytical monitoring. By framing maintenance not as a cost but as a crucial investment, this examination seeks to provide a comprehensive framework for owners and operators to enhance equipment durability, reduce unscheduled downtime, and ultimately improve the financial return on their capital investment.

Principaux enseignements

  • Understand your machine's core systems—hydraulics, PLC, and vibration—to diagnose issues early.
  • Implement a strict, multi-interval maintenance schedule covering daily, weekly, and monthly tasks.
  • Train operators thoroughly, as their skill is the first line of defense against premature wear.
  • Control the machine's operating environment by mitigating dust, humidity, and power surges.
  • A data-driven approach to maintenance can significantly extend the lifespan of a brick machine.
  • Strategically upgrade components like PLCs and molds to enhance durability and efficiency.
  • Use only high-quality raw materials to reduce abrasive wear on critical machine parts.

Table des matières

Foundational Understanding: The Anatomy and Physics of Your Machine

To ask about the lifespan of a brick machine is to pose a question not merely about time, but about potential. It is to inquire into the very nature of a machine’s existence, from its initial commissioning to its eventual retirement. The answer is not a single number but a spectrum of possibilities, shaped profoundly by our understanding and our actions. A brick-making machine is not a simple, monolithic entity; it is a complex ecosystem of interconnected systems. To truly grasp how to extend its life, we must first embark on a journey inward, to understand its anatomy and the physical principles that animate it. This initial act of understanding is the first, and perhaps most significant, step toward stewardship and longevity. Without this foundational knowledge, any maintenance effort is merely a series of disconnected tasks rather than a coherent strategy. A deeper appreciation for the machine's internal workings transforms an operator from a simple user into an informed guardian of a critical asset, capable of interpreting the machine's subtle signals and responding with foresight.

The Core Components: A Deeper Look

At the heart of every modern concrete block machine lies a quartet of systems working in concert. Thinking of them through an analogy can be helpful. The hydraulic system is the machine's powerful musculature, the Programmable Logic Controller (PLC) is its intelligent brain, the vibration system is its rhythmic heartbeat, and the mold assembly represents its dextrous hands.

The hydraulic system generates the immense force required to compact the concrete mixture into a dense, solid block. It consists of a motor, a pump, valves, cylinders, and hydraulic fluid. The health of this system is paramount. The pump, often a variable displacement piston pump in higher-end models, is the prime mover. It pressurizes the hydraulic fluid, which is then directed by solenoid valves to the cylinders that press the tamper head onto the material in the mold. The pressure, speed, and timing of these actions are not arbitrary; they are precisely calculated to achieve optimal compaction. Any degradation in this system—a slow leak in a seal, contaminated fluid, or a worn pump—diminishes the machine's ability to produce consistent, high-quality bricks and, over time, places cumulative stress on the entire structure. Understanding this system means recognizing that a small, weeping hydraulic fitting is not a minor nuisance but a symptom of a potential systemic issue that can shorten the overall lifespan of a brick machine.

The PLC, often a robust unit from manufacturers like Siemens as seen in many high-quality machines ([hfbrickmachine.com]), is the central nervous system. It receives inputs from various sensors—proximity switches that detect the pallet's position, pressure transducers in the hydraulic lines, and timers—and executes a pre-programmed sequence of commands to the valves, motors, and vibrators. Its function is one of pure logic and precision. The integrity of the PLC and its associated wiring is a direct determinant of the machine's reliability. While the PLC itself is a solid-state device with a very long intrinsic lifespan, its vulnerability lies in its connections to the outside world: the electrical cabinet it resides in. Dust, moisture, and voltage fluctuations are the primary threats that can lead to phantom faults, operational errors, and, in the worst case, permanent damage to the control unit.

The vibration system is what facilitates the consolidation of the concrete mix, ensuring that aggregates settle into a dense matrix and eliminating voids. It typically involves powerful, eccentric-weight electric motors mounted either to the mold table or directly to the mold. When these motors spin, they create a high-frequency vibration that fluidizes the semi-dry concrete mix. The harmony between the vibration frequency, amplitude, and the applied hydraulic pressure is a delicate art and science. An imbalance here not only results in poor-quality bricks but also transmits destructive resonant frequencies throughout the machine's frame, accelerating metal fatigue and loosening critical fasteners. The bearings within these vibration motors are under immense stress and are a common point of failure if not properly specified and maintained.

Finally, the block moulds and the associated tamper head are the tools that directly shape the product. These components are subjected to the most direct and brutal forms of wear: high-pressure compaction and intense abrasion from the raw materials. The quality of the steel used, the precision of their machining, and the heat treatment processes they undergo are direct indicators of their durability. A worn mold will produce bricks with inconsistent dimensions and poor finish, but more subtly, it can also cause uneven loading on the press, contributing to the wear of guide bushings and columns.

The Physics of Compaction and Vibration

The creation of a durable concrete block is a physical process governed by principles of soil mechanics and material science. A semi-dry mix of cement, sand, aggregate, and water is not simply squeezed into shape. The process is far more nuanced. Initially, the mold is filled with the mixture. Then, the vibration begins. The purpose of this vibration is to reduce the inter-particle friction within the mix. Imagine a jar full of pebbles; shaking the jar allows the pebbles to settle into a much denser configuration. Similarly, the vibration allows the sand and aggregate particles to overcome their static friction and rearrange themselves into a tightly packed state, expelling trapped air.

While the material is in this "fluidized" state, the hydraulic press applies immense pressure via the tamper head. This pressure forces the particles even closer together, squeezing out more air and excess water. The combination of precisely timed vibration and pressure is what achieves a high-density, low-porosity block with excellent compressive strength.

Understanding this process reveals how operational errors can damage the machine. For instance, if an operator applies hydraulic pressure before the vibration has had enough time to consolidate the mix, the hydraulic system must work against a much stiffer, less compliant material. This results in a pressure spike throughout the hydraulic circuit, stressing the pump, hoses, and fittings. Over thousands of cycles, this seemingly minor operational error contributes significantly to the premature aging of the hydraulic system. Conversely, vibrating for too long or at the wrong frequency can cause segregation of the aggregates, leading to weak bricks and placing unnecessary wear on the vibration motors and the machine frame. The optimal lifespan of a brick machine is therefore intrinsically linked to operating it in a way that respects these physical limits.

Material Science: How Raw Materials Impact Machine Wear

The raw materials used in brick production are not inert passengers in the process; they are active agents of wear. Sand and crushed stone aggregates are, by their nature, highly abrasive. The primary component of sand is silica (silicon dioxide), a very hard mineral. As this material is transported by conveyors, mixed in a concrete mixer, and fed into the mold, it is constantly grinding away at every surface it touches.

Consider the journey of the aggregate. It starts in the batching system, often a component of a larger efficient concrete batching plant, where it is weighed and dropped onto a conveyor belt. The sharp edges of the aggregate slowly cut and gouge the belt's surface. It then enters the concrete mixer, where it is violently churned with cement, water, and other materials. The interior of the mixer, particularly the mixing paddles and liners, is a high-wear environment. If the paddles are not made from a sufficiently hard, abrasion-resistant alloy like chromium steel, their lifespan will be drastically shortened.

From the mixer, the material travels to the brick machine's hopper and then into the mold. This is where the most intense wear occurs. As the material fills the mold, it scrapes against the inner walls. When the tamper head descends, it grinds the aggregate between its face and the top surface of the mold partitions. The choice of steel for these components is therefore not a trivial matter. Standard carbon steel would be worn away in a remarkably short time. High-end manufacturers use specialized tool steels or apply case-hardening treatments that create an extremely hard outer layer (often measured on the Rockwell hardness scale) to resist this abrasion. The lifespan of a brick machine is directly proportional to the quality of the wear-resistant materials used in its construction. Even the moisture content of the mix plays a role; a mix that is too dry will be more abrasive than one with the optimal water content.

Composant Common Wear Patterns Primary Cause(s) Mitigation Strategy
Mold Box & Tamper Head Rounding of corners, dimensional loss, surface scoring Abrasion from aggregates (sand, gravel) during compaction Use of high-hardness, heat-treated steels (e.g., Hardox, carburized steel); regular inspection and rotation; timely replacement.
Hydraulic Pump Internal leakage, pressure loss, increased noise Fluid contamination (dirt, water), fluid overheating, cavitation (air in the system) Strict fluid filtration schedule; use of oil coolers; regular checks for leaks in the suction line; periodic oil analysis.
Vibration Motors Bearing failure (noise, seizure), winding burnout Imbalance, overloading, contamination of bearings, voltage fluctuations Regular lubrication of bearings; ensuring balanced loads; keeping motors clean; using a stable power supply.
PLC & Sensors Intermittent faults, input/output failure Concrete dust ingress, moisture, electrical surges, physical vibration House in a sealed, positive-pressure cabinet; use of surge protectors and line conditioners; ensure proper grounding.
Conveyor Belts Surface cuts and gouges, edge fraying, mistracking Sharp aggregates, improper loading (material dropping from too high), misalignment Install skirtboards and soft-loading chutes; regular roller alignment checks; use of heavy-duty, multi-ply belts.

The Cornerstone of Longevity: A Rigorous Maintenance Protocol

If foundational understanding is the mind of machine care, then a rigorous maintenance protocol is its disciplined body. A machine left to its own devices, even one built with the finest materials, will inevitably succumb to the forces of friction, vibration, and corrosion. Maintenance is the active, ongoing intervention that counteracts this natural entropy. It is not something to be done when time allows; it is a core operational function, as vital as production itself. A well-designed maintenance program is proactive, not reactive. It aims to prevent failures rather than simply fix them after they occur. This philosophy shift is central to maximizing the lifespan of a brick machine and, by extension, the profitability of the entire operation. The costs associated with reactive maintenance—unscheduled downtime, lost production, expedited shipping for emergency parts, and cascading damage—dwarf the investment required for a proactive program (Swanson, 2001).

Daily, Weekly, Monthly, and Annual Checks

A successful maintenance protocol is built on rhythm and regularity. It breaks down the monumental task of caring for a complex machine into manageable, repeatable actions scheduled at different intervals.

Daily Checks (Pre-operation): This is a brief but critical 15-minute walk-around. The operator, as the person most intimately familiar with the machine, is best suited for this. The goal is to catch small problems before they escalate. This includes a visual inspection for any hydraulic or oil leaks, particularly around fittings and seals. A single drop of hydraulic fluid can indicate a fitting that is beginning to loosen or a seal that is starting to fail. They should check the tension and condition of any drive belts and chains. A loose chain can cause jerky movements and shock-loading, while a frayed belt is a breakdown waiting to happen. All safety guards and emergency stops must be verified to be in place and functional. Finally, the operator should listen to the machine as it starts up. Any new or unusual noises—a whine from a pump, a rattle from a guard, a grinding from a bearing—are early warnings that demand investigation. After the production day, a thorough cleaning to remove all concrete residue is not just for appearance; it is a critical maintenance task.

Weekly Checks: These are more in-depth. All key lubrication points should be greased according to the manufacturer's chart. This is a moment for mindful action, not just pumping grease until it oozes out. Over-greasing can be as harmful as under-greasing, as it can damage seals and attract dirt. All accessible bolts and fasteners, particularly on the mold assembly and vibration table, should be checked for tightness. The intense vibration of the machine will inevitably work fasteners loose over time. The hydraulic fluid level in the reservoir should be checked when the fluid is cool and all cylinders are retracted. The condition of the hydraulic hoses should be inspected for any signs of abrasion, cracking, or bulging.

Monthly Checks: This interval focuses on systems that change more slowly. The hydraulic system's filter is a key item. Most machines have a filter condition indicator that will show when the filter is becoming clogged and needs to be replaced. Ignoring this leads to the pump working harder and dirty fluid circulating through the system, dramatically accelerating wear on pumps and valves. The electrical cabinet should be opened (with power locked out) and cleaned of any accumulated dust using a vacuum or low-pressure compressed air. All electrical terminals should be visually inspected for tightness and any signs of overheating (discoloration). The calibration of critical sensors, like pressure transducers or proximity switches, should be checked to ensure the machine is operating to its specified parameters.

Annual Checks: This is a time for a major health check-up, often coinciding with a planned shutdown. It's advisable to have this inspection performed or supervised by a qualified technician, perhaps from the original manufacturer. This includes taking a sample of the hydraulic oil and sending it for analysis. This analysis can reveal the health of the oil, the presence of contaminants (like water or metal particles), and provide an early warning of wear in the pump or cylinders. Key wear components like the main guide bushings and columns for the press should be measured for wear. The structural frame of the machine should be inspected for any signs of cracks, particularly around welds in high-stress areas. This is also a good time to perform any recommended major component overhauls and install any available software updates for the PLC.

Interval Key Tasks Rationale
Quotidiennement Visual inspection for leaks (hydraulic, oil). Check belt/chain tension. Verify safety guards/E-stops. Listen for unusual noises. End-of-day cleaning. Catches small issues before they become major failures. Ensures operator safety. Prevents accumulation of corrosive/abrasive material.
Hebdomadaire Lubricate all grease points. Check tightness of critical bolts (mold, vibrators). Inspect hydraulic hoses for wear. Check hydraulic fluid level. Prevents wear on moving parts. Mitigates risk from vibration-induced loosening. Prevents catastrophic hose failure.
Mensuel Replace hydraulic filters as needed. Clean electrical cabinets. Inspect electrical terminals for tightness/heat. Check sensor calibration. Ensures hydraulic system health and longevity. Prevents electrical faults and fires. Maintains operational accuracy and brick quality.
Annual Professional technician inspection. Hydraulic oil analysis. Measure critical wear parts (bushings, columns). Inspect frame for fatigue cracks. Provides expert assessment and predictive failure analysis. Verifies structural integrity. Plans for major component replacement.

The Critical Role of Lubrication

Lubrication is the lifeblood of any mechanical system. Its primary function is to create a thin film between moving surfaces to reduce friction and wear. In a brick machine, which combines high loads and intense vibration, its role is magnified. However, not all lubricants are created equal, and their correct application is a science.

The two main categories are oils and greases. Oils, like the hydraulic fluid that fills the main system, are used in enclosed systems where they can be circulated, cooled, and filtered. The viscosity of the hydraulic oil is a critical parameter. Viscosity is a measure of a fluid's resistance to flow. An oil with too low a viscosity for the operating temperature will not provide an adequate film, leading to metal-to-metal contact and wear. An oil with too high a viscosity will be difficult to pump, leading to sluggish operation and energy waste. The manufacturer's recommendation (e.g., ISO VG 46 or VG 68) is based on the pump's design and expected operating temperatures and must be strictly followed.

Greases are essentially oils suspended in a thickener (like a soap). The thickener acts like a sponge, holding the oil in place for applications where a circulating oil bath is not practical, such as in the bearings of vibration motors or on guide columns. The choice of grease is equally important. A high-temperature, high-pressure grease with solid additives like molybdenum disulfide might be required for the heavily loaded press guide bushings, while a different type of grease might be specified for the higher-speed motor bearings. The concept of lubricant compatibility is also vital; mixing different types of greases can cause the thickeners to break down, releasing the oil and leaving the component unprotected. A disciplined approach to lubrication, guided by a clear chart specifying the type, amount, and frequency for each point, is a non-negotiable part of extending the lifespan of a brick machine.

Cleaning: More Than Just Aesthetics

In the dusty, gritty environment of concrete production, cleaning is a fundamental maintenance task, not a janitorial one. The accumulation of cement dust and fine aggregates has multiple destructive effects.

First, cement dust is hygroscopic, meaning it attracts and holds moisture from the air. When this damp dust cakes onto the steel frame of the machine, it holds moisture against the painted or unpainted surfaces, dramatically accelerating corrosion. What might start as surface rust can, over years, penetrate deeper and compromise the structural integrity of a weld or a panel.

Second, this caked-on material acts as an insulator. Components like electric motors and hydraulic pumps are designed to dissipate heat into the surrounding air. A thick layer of dust-turned-concrete prevents this, causing the components to run hotter than designed. For an electric motor, every 10°C increase in operating temperature above its design limit can cut the life of its windings in half. For hydraulic fluid, excessive heat accelerates its oxidation, reducing its lifespan and creating harmful sludge and varnish that can clog fine tolerances in valves.

Third, the dust is abrasive and invasive. It works its way into the seals on hydraulic cylinders and bearings. Once inside, these fine, hard particles act like a grinding paste, quickly destroying the smooth surfaces they are meant to protect. This leads to leaking cylinders and failed bearings. It can also find its way into electrical enclosures, coating circuit boards and relays. When combined with a little humidity, this conductive dust can create short circuits, leading to inexplicable and frustrating control system failures.

A daily routine of blowing down the machine with compressed air (while wearing proper respiratory protection) and scraping off any stubborn buildup is essential. Particular attention should be paid to cleaning cooling fins on motors and around any moving shafts or seals. This simple act of daily cleaning is one of the highest-return investments one can make in the long-term health and lifespan of a brick machine.

Operational Excellence: Training and Skillful Operation

A brick machine, no matter how automated or robustly built, is not an autonomous entity. It is a tool, and like any tool, its effectiveness and longevity are profoundly influenced by the skill and care of the person wielding it. We can invest in the finest German steel for our block moulds and the most advanced PLC systems, but if the operator is untrained or careless, that investment is jeopardized. Operational excellence, fostered through comprehensive training and disciplined procedures, is a critical pillar supporting the maximum lifespan of a brick machine. An operator is not merely a button-pusher; they are the machine's daily partner and first diagnostician. Their sensory inputs—what they see, hear, and even feel through the machine's vibrations—provide a continuous stream of real-time data on the machine's health.

The Operator as the First Line of Defense

The idea of the operator as a "first line of defense" reframes their role from a passive user to an active steward. A well-trained operator develops a deep, almost intuitive connection with their machine. They know its normal operating sounds: the healthy hum of the hydraulic pump, the specific frequency of the vibrators, the clean "thump" of the tamper head seating. Because they are attuned to this baseline, they are the first to notice a deviation. A new high-pitched whine could signal cavitation in the pump, a precursor to serious damage. A change in the vibration sound might indicate a failing bearing in one of the motors. A slight hesitation in a hydraulic movement could point to a sticking valve.

To cultivate this level of awareness, training must go beyond the basic "how to start and stop" instructions. It must include a basic understanding of how the machine works, covering the core components discussed earlier. When an operator understands that the hydraulic system relies on clean, cool fluid, they are more likely to notice and report a small leak or an overheating power pack. When they understand the destructive power of vibration, they are more likely to report a loose guard or a rattling component. This training empowers the operator, giving them the confidence and the vocabulary to report issues accurately and early. This early reporting is invaluable. Fixing a loose hydraulic fitting costs almost nothing; replacing a pump that failed due to fluid starvation costs thousands and halts production for days. The difference between these two outcomes is often a vigilant operator.

Establishing Standard Operating Procedures (SOPs)

Human memory is fallible, especially under pressure. Relying on operators to simply "remember" the correct way to perform complex tasks is a recipe for inconsistency and error. Standard Operating Procedures (SOPs) are the antidote. They are detailed, step-by-step written instructions for all routine and critical tasks associated with the concrete block machine.

SOPs should be developed for:

  • Startup Sequence: The correct order for turning on power, enabling the hydraulic system, and starting ancillary equipment like conveyors. A wrong sequence could, for example, start a conveyor feeding material into a machine that isn't ready for it, causing a massive jam.
  • Shutdown Sequence: The proper procedure for clearing the machine of material, shutting down systems to minimize stress, and performing end-of-day cleaning.
  • Mold Changes: Changing block moulds is a frequent but high-risk operation. An SOP ensures that the mold is correctly aligned, securely fastened, and that the height and pressure settings are properly adjusted for the new mold. A misaligned mold can lead to it being struck and damaged by the tamper head—a very expensive mistake.
  • Clearing Jams: Material jams are inevitable. An SOP for clearing them that emphasizes lock-out/tag-out safety procedures and using the correct tools prevents both injury to the operator and damage to the machine. Trying to clear a jam with a steel bar while the machine is powered on is a common cause of both severe accidents and damaged equipment.
  • Emergency Procedures: Clear, simple instructions for what to do in case of an emergency stop, hydraulic line rupture, or fire.

These documents should be clear, concise, and readily available at the machine. Using pictures and diagrams can greatly enhance clarity. SOPs ensure that every operator, regardless of experience level, performs tasks in the same safe, efficient, and machine-friendly way. They are the foundation of operational consistency, which is a key ingredient in achieving a long and predictable lifespan of a brick machine.

The Perils of Overloading and "Pushing the Limits"

In a production environment, there is always a temptation to produce more, faster. This often translates into operators or supervisors attempting to "tweak" the machine to shorten cycle times or increase the compaction force beyond the manufacturer's specified limits. While this might yield a short-term increase in output, it is a profoundly short-sighted strategy that drastically reduces the machine's lifespan.

Every component in a brick machine—the frame, the hydraulic pump, the motors, the bearings—is designed to withstand a certain amount of force and stress over a calculated number of cycles. This is known as its fatigue life. When you operate the machine beyond its design parameters, you are not just slightly increasing the wear; you are often exponentially consuming its fatigue life.

Consider the hydraulic system. If the machine is designed for a maximum working pressure of 2500 PSI, and it is "tweaked" to run at 3000 PSI to get a slightly denser brick, the stress on every single component in that system—the pump internals, the hose fittings, the cylinder seals—is significantly increased. Metal fatigue is not a linear process. A 20% increase in stress can reduce the fatigue life of a component by 50% or more (Schijve, 2009). This means that a pump designed to last for ten years might fail in five, or a hose designed for a decade of service might rupture in a few years.

Similarly, shortening the cycle time by reducing the dwell time for vibration or pressing means the machine's movements become more abrupt. The acceleration and deceleration forces on all moving parts increase, leading to shock-loading. This sends jarring impacts through the entire machine, stressing welds, loosening bolts, and shortening the life of bearings and bushings. The pursuit of a few extra bricks per hour comes at the cost of years of the machine's operational life. A core part of operational excellence is instilling the discipline to run the machine within its designed and proven parameters, recognizing that the true measure of performance is not just hourly output, but reliable output over a decade or more. This discipline is a cornerstone of maximizing the lifespan of a brick machine.

The Unseen Enemy: Mitigating Environmental and Electrical Factors

When we consider the longevity of a heavy industrial apparatus like a brick machine, our attention is naturally drawn to the visible, mechanical forces at play: the immense pressure of the hydraulics, the abrasion of the aggregates, the vibration shaking the frame. Yet, some of the most persistent and damaging threats to the lifespan of a brick machine are the invisible ones. The quality of the air surrounding the machine, the stability of the electrical current that powers it, and the solidity of the ground beneath it are all potent factors that can quietly conspire to shorten its operational life. Attending to these environmental and electrical factors is a mark of a truly comprehensive approach to asset preservation, moving beyond the machine itself to control the ecosystem in which it operates.

Climate and Environmental Control

A brick machine is a creature of steel, and steel's ancient enemy is oxidation, or rust. The rate of this chemical reaction is governed by the presence of oxygen and an electrolyte, which in most industrial settings is water. Therefore, the ambient humidity of the operating environment is a direct determinant of the rate of corrosion. In a coastal region or a tropical climate with high humidity, unprotected steel surfaces can begin to show signs of rust in a matter of days. While most machines are protected by industrial-grade paint, this coating is inevitably breached by scratches, nicks, and the general wear and tear of operation. Once moisture gets under the paint, it can spread, causing the paint to bubble and flake off, exposing ever-larger areas of the steel frame to corrosion. Over years, this can lead to a significant loss of structural thickness and strength.

The second environmental aggressor is dust. As discussed, concrete and cement dust are not benign. Beyond their abrasive and insulating properties, they can combine with humidity to create a caustic, concrete-like crust that is difficult to remove and actively promotes corrosion.

The solution is to provide the machine with a controlled environment. The ideal setup is to house the entire brick-making operation, including the concrete mixer and aggregate storage, inside a well-ventilated building. This protects the equipment from direct rain and sun, which can degrade paint, rubber hoses, and electrical wiring. More importantly, it allows for control of airborne dust. A dust collection system, with hoods placed over key dust-generating points like the mixer and the conveyor transfer points, can dramatically reduce the amount of particulate matter in the air. This not only creates a healthier and safer environment for workers but also starves the machine of the abrasive and corrosive dust that shortens its life. Proper ventilation also helps to manage humidity levels, reducing the time that surfaces remain damp and susceptible to rust. Protecting a machine from the elements is a fundamental step in ensuring a long lifespan of a brick machine.

Power Quality: The Silent Killer of Electronics

Modern brick machines are not just mechanical beasts; they are sophisticated electromechanical systems governed by sensitive electronics. The PLC, variable frequency drives (VFDs) for motors, sensors, and solenoid valves all rely on a clean, stable supply of electricity to function correctly and reliably. Unfortunately, the power supplied by the grid, especially in industrial areas or remote locations, is often anything but clean. It can be subject to a host of disturbances that can slowly degrade or instantly destroy electronic components.

  • Voltage Spikes (Transients): These are very brief but very high-voltage events, often caused by lightning strikes miles away or the switching of large industrial motors on the same power grid. A significant spike can arc across and instantly destroy the delicate microcircuits inside a PLC or sensor.
  • Voltage Sags (Brownouts): These are temporary drops in voltage, often caused by the startup of large motors. During a sag, motors can overheat, and power supplies for electronic systems can fail to regulate properly, leading to unpredictable behavior and crashes.
  • Electrical Noise: This is high-frequency interference superimposed on the main power waveform, often generated by VFDs, welders, or other industrial equipment. This "dirty power" can interfere with the low-voltage signals used by sensors and communication lines, causing phantom errors and erratic operation.

Protecting the machine from these electrical threats is a critical investment. The first step is proper grounding. A dedicated, low-resistance grounding rod for the machine's electrical system provides a safe path for stray currents and can help dissipate some electrical noise. Second, the installation of a high-quality surge protection device (SPD) at the main power inlet for the machine is essential to clamp down on voltage spikes. For the most sensitive components, like the PLC, using an uninterruptible power supply (UPS) or a power line conditioner can provide the ultimate protection. A UPS not only protects against spikes and noise but also bridges the gap during short power sags, allowing the machine to ride through the disturbance or shut down gracefully. Ignoring power quality is like letting a silent, invisible saboteur attack the brain and nervous system of your machine every day.

Foundation and Stability

The very principle of a brick machine's operation—intense, high-frequency vibration—makes the quality of its foundation a crucial factor in its long-term health. The machine is designed to impart vibrational energy into the mold and the concrete mix, not into its own frame or the floor. A solid, properly engineered concrete foundation is required to absorb and dampen these forces.

If the machine is installed on a foundation that is too thin, improperly reinforced, or on unstable ground, the foundation itself can begin to act like a springboard. Instead of dampening the vibrations, it reflects them back into the machine's structure. This creates a host of problems. The reflected energy causes the entire machine frame to shake more violently than it was designed to, putting immense stress on all welded joints and bolted connections. This can lead to premature metal fatigue and the development of cracks in the frame.

Furthermore, an unstable foundation can lead to the machine settling unevenly over time. Even a slight tilt that is imperceptible to the naked eye can cause significant issues. It can throw the alignment of the main press guide columns out of true, causing the tamper head to bind as it moves, leading to excessive wear on the expensive guide bushings and columns. It can cause conveyor belts to mistrack and material to feed unevenly into the mold. The manufacturer's specifications for the foundation are not mere suggestions; they are a critical engineering requirement for the machine's proper function and longevity. Investing in a robust, level foundation is literally building a stable base for a long and productive lifespan of a brick machine.

Strategic Component and Spare Parts Management

A brick machine is a system where the whole is only as strong as its weakest part. Even with the most diligent maintenance and skilled operation, some components are designed to wear and be replaced over time. The philosophy of "wear parts" is fundamental to modern machine design; it is more economical to design a machine with a few inexpensive, easily replaceable components that absorb the brunt of the wear than to try and make every single part last forever. A strategic approach to managing these components—identifying them, sourcing high-quality replacements, and maintaining an intelligent inventory—is essential for minimizing downtime and controlling the total cost of ownership over the machine's life. This strategic foresight transforms maintenance from a reactive scramble into a planned, efficient process.

Identifying High-Wear Components

The first step in strategic component management is to develop a deep understanding of which parts on your specific machine model are subject to the most rapid wear. While this varies between manufacturers, a common set of sacrificial components exists on most concrete block machines.

  • Block Moulds and Tamper Heads: As discussed, these are at the coalface of abrasion and compaction. They are arguably the most critical wear part, as their condition directly affects the quality and dimensions of the final product. Their lifespan is measured not in years, but in the number of cycles or bricks produced.
  • Hydraulic Seals and Hoses: The seals inside hydraulic cylinders and on the piston rods are constantly moving under high pressure. Over time, they harden, lose their elasticity, and begin to leak. Hydraulic hoses, even when not physically abraded, degrade from the inside out due to the constant pressure cycles and the chemical effects of the hot hydraulic fluid.
  • Vibration Motor Bearings: The bearings that support the shafts of the powerful vibration motors are under some of the highest stress in the entire machine. Despite being robustly designed, their lifespan is finite and they are a common failure point.
  • Conveyor Belts, Rollers, and Scrapers: The system that transports raw materials from the concrete mixer to the brick machine's hopper is in a constant battle with abrasion. The belt itself, the idler rollers it runs on, and the scrapers used to clean it are all subject to rapid wear.
  • Mixer Liners and Paddles: Inside the concrete mixer, the replaceable liner plates that protect the mixer's shell and the mixing paddles (or stars) are designed to be worn away by the churning aggregate. Their job is to be destroyed so that the main structure of the mixer is preserved.
  • Proximity Sensors and Limit Switches: These small electrical components, which detect the position of pallets, the tamper head, and other moving parts, have a finite life. They are subject to intense vibration and are often located in harsh, dusty areas, leading to eventual failure.

Creating a list of these high-wear parts for your specific machine, complete with part numbers and typical lifespans (tracked through your own data), is the foundational document for your spare parts strategy.

The OEM vs. Aftermarket Parts Debate

Once you have identified the parts you will inevitably need to replace, the question of sourcing arises. Do you buy Original Equipment Manufacturer (OEM) parts directly from the company that built your machine, or do you source them from a third-party aftermarket supplier? This is not a simple question of cost, but a complex calculation of risk, quality, and value.

OEM Parts: The primary advantage of OEM parts is the guarantee of quality, fit, and performance. The manufacturer has designed the part specifically for your machine, using materials and tolerances that they have determined are optimal. When you buy an OEM hydraulic seal kit or a set of block moulds, you can be confident that it will fit perfectly and perform as the original did. This can be particularly important for complex or highly stressed components. The downside, of course, is that OEM parts typically come with a premium price tag.

Aftermarket Parts: The aftermarket offers a vast landscape of suppliers, often at significantly lower prices. This can be very tempting for budget-conscious operations. However, the quality can vary dramatically. A high-quality aftermarket supplier might produce a part that is equal to, or in some cases even superior to, the OEM part (for example, by using an even more advanced wear-resistant alloy for a mixer paddle). On the other hand, a low-quality supplier might use inferior materials, have poor quality control, or imprecise dimensions. Installing a cheap, poorly made aftermarket hydraulic pump might save money upfront, but if it fails prematurely and sends metal debris throughout your entire hydraulic system, the resulting damage could cost ten times the initial savings.

The prudent approach is a nuanced one. For the most critical, high-stress, or complex components (e.g., the PLC, a main hydraulic pump, precision-machined mold components), sticking with the OEM is often the safest and most cost-effective long-term strategy. For simpler, standardized wear items (e.g., bearings, belts, some types of hydraulic fittings, or even raw steel for fabricating liners), high-quality aftermarket suppliers can offer excellent value. The key is to thoroughly vet any aftermarket supplier. Ask for material specifications, case studies from other customers, and quality certifications. Never choose a supplier based on price alone.

Building a "Smart" Spare Parts Inventory

Downtime is the enemy of profitability. Having a machine sit idle for three days while waiting for a critical part to be shipped is an expensive failure of planning. At the same time, tying up huge amounts of capital by having two of every component sitting on a shelf is inefficient. A "smart" inventory strategy seeks the optimal balance.

This strategy is based on two key metrics for each part: its criticality and its lead time.

  • Criticality: How severe is the impact if this part fails? A failed vibration motor bearing will shut down the entire machine (high criticality). A worn conveyor belt scraper might reduce cleaning efficiency but allow production to continue for a short time (low criticality).
  • Délai d'exécution : How long does it take to get a replacement part, from the moment you order it to the moment it is in your hands? A standard bearing might be available from a local supplier in an hour (short lead time). A custom-fabricated mold from an overseas manufacturer might take eight weeks (long lead time).

By plotting each wear part on a matrix of criticality and lead time, you can define your inventory policy:

  • High Criticality / Long Lead Time: These are the parts you must keep in stock. This includes items like a spare set of vibration motors, a spare PLC, or at least one complete set of the most commonly used block moulds. The cost of holding them is far less than the cost of the extended downtime their failure would cause.
  • High Criticality / Short Lead Time: You may not need to stock these parts, but you must have a pre-established, reliable local supplier. Know who they are, have an account set up, and confirm they typically stock the item.
  • Low Criticality / Long Lead Time: These can often be ordered on a regular, planned basis. For example, if you know your mixer liners last about 12 months, you can place an order for a new set at the 10-month mark.
  • Low Criticality / Short Lead Time: There is no need to stock these items. They can be purchased as needed.

This intelligent approach ensures that you are protected against the most damaging forms of downtime without needlessly inflating your inventory costs, contributing to a more resilient and financially sustainable operation over the full lifespan of a brick machine.

The Power of Upgrades and Modernization

A brick machine purchased in 2015 is not necessarily condemned to the technology of 2015 for its entire life. The concept of lifespan is not just about preservation but also about adaptation. Strategic upgrades and modernization can breathe new life into an aging machine, enhancing its performance, improving its reliability, and extending its useful economic life far beyond its original expectations. In many cases, retrofitting an older, mechanically sound frame with modern components can provide performance and efficiency comparable to a new machine at a fraction of the cost. This approach views the machine not as a static object but as a dynamic platform for improvement, a philosophy that is key to long-term competitiveness.

Retrofitting for Efficiency and Durability

The heavy steel frame of a brick machine, if properly cared for and free from fatigue cracks, has an extremely long potential lifespan. It is often the systems attached to this frame that become obsolete or wear out. Retrofitting involves selectively replacing these older systems with their modern counterparts.

One of the most impactful upgrades is to the control system. An older machine might operate using a complex web of electro-mechanical relays and timers. This "relay logic" is difficult to troubleshoot, inflexible, and prone to mechanical failure. Retrofitting a modern PLC-based control system is a transformative upgrade. A PLC is more reliable, allows for much more precise and complex control sequences (which can improve brick quality), and offers powerful diagnostic capabilities. A fault that might take hours to trace through a relay panel can often be identified in seconds on a PLC's diagnostic screen. This single upgrade can dramatically reduce electrical troubleshooting downtime.

Another area ripe for retrofitting is materials technology. The science of wear-resistant materials is constantly advancing. A machine from a decade ago may have been built with the best steel available at the time, but superior alloys likely exist today. For example, when it comes time to replace worn-out block moulds or mixer paddles, one could choose to replace them not with identical OEM parts, but with upgraded versions made from a more advanced, harder, or tougher steel alloy. This might involve a higher initial cost, but if the new mold lasts 50% longer, the lifetime cost is lower, and the machine spends less time down for mold changes. Similarly, older hydraulic components can be replaced with more efficient, modern versions that consume less energy and generate less heat.

Software and Control System Updates

For machines that are already equipped with a PLC, the software that runs it is a powerful, yet often overlooked, component. Just as your smartphone receives updates that fix bugs and add new features, machine manufacturers sometimes develop updated software versions for their equipment. These updates can be a source of significant, low-cost performance enhancement.

A software update might include:

  • Optimized Cycle Logic: Engineers may find a way to shave a fraction of a second off a movement or overlap certain actions in a way that shortens the overall cycle time without adding mechanical stress. Over a full day's production, this can add up to a significant increase in output.
  • Improved Diagnostic Features: An update might add more detailed error messages, helping operators and technicians pinpoint problems faster. For example, instead of a generic "Hydraulic Fault" message, an updated system might specify "Pressure Transducer Signal Out of Range," directing the technician immediately to the specific sensor.
  • New "Recipes": For machines producing a variety of products, a software update might allow for more "recipes" to be stored, making it faster and less error-prone to switch between producing hollow blocks, solid pavers, or other items.
  • Reduced Mechanical Stress: Updates can refine the acceleration and deceleration profiles of hydraulic movements (a feature known as "soft-shifting"), resulting in smoother operation with less shock-loading on the frame and components.

It is wise to maintain a relationship with the machine manufacturer and periodically inquire about the availability of any software or firmware updates for your specific model. The cost of having a technician install an update is often negligible compared to the potential gains in efficiency and the extension of the machine's mechanical life.

Integrating with Ancillary Equipment

The lifespan of a brick machine cannot be considered in isolation. It is part of a larger production ecosystem, and the quality and performance of the equipment that feeds it have a direct impact on its health. The most important ancillary system is the one that prepares the concrete mix: the batching and mixing plant.

Integrating the brick machine with a high-quality, fully automated system, such as a modern centrale à béton, is a powerful way to enhance and protect the brick machine itself. An automated batching plant ensures that every single batch of concrete delivered to the machine is perfectly consistent in its proportions of cement, aggregate, sand, and water. This consistency is vital.

A mix with too much water can lead to sloppy bricks that are difficult to handle and can cause material buildup in the mold. A mix that is too dry is highly abrasive and requires more compaction force, putting extra strain on the hydraulic system and accelerating mold wear. A mix with improperly graded aggregates can cause jams in the feed box. These inconsistencies from a poorly controlled mixing operation create a chaotic operating environment for the brick machine, subjecting it to a constant stream of minor shocks and stresses that accumulate over time.

In contrast, when a brick machine is fed a consistently perfect mix from a reliable asphalt plant or concrete plant, it can operate in a smooth, steady rhythm. The hydraulic pressures remain consistent, the vibration required is predictable, and the flow of material is uniform. This stable state is the ideal condition for a long and trouble-free operational life. Therefore, investing in high-quality ancillary equipment is not just about the efficiency of those individual units; it is a direct investment in maximizing the lifespan of a brick machine.

Data-Driven Decisions: Monitoring, Analysis, and Predictive Maintenance

In the 21st-century industrial landscape, the most successful enterprises are those that have learned to listen to their data. The final and most advanced frontier in extending the life of a brick machine lies in moving beyond scheduled, preventative maintenance and into the realm of predictive maintenance (PdM). This approach uses data collected from the machine to forecast failures before they happen, allowing for planned, minimally disruptive interventions. It represents a paradigm shift from a philosophy of "preventing failure" to one of "predicting and managing failure." This data-driven strategy allows for the optimization of maintenance resources, the near-elimination of unscheduled downtime, and the ability to safely push components to their true maximum useful life, rather than replacing them based on a conservative, one-size-fits-all schedule.

Beyond Simple Record-Keeping

The foundation of any data-driven strategy is, of course, data. For many operations, maintenance records consist of a paper logbook in the corner of the workshop, with greasy-thumbed entries like "greased machine" or "replaced hose." While better than nothing, this type of record-keeping lacks the structure and detail needed for meaningful analysis.

The first step is to digitize and structure your record-keeping. This can be done with a simple spreadsheet or, for larger operations, a dedicated Computerized Maintenance Management System (CMMS). For every maintenance action, you should record:

  • Date and Time
  • Machine Operating Hours/Cycles at the time of the event
  • The Specific Component involved (using consistent naming and part numbers)
  • The Problem Observed (e.g., "loud whining noise from pump," "hydraulic fluid leak at cylinder rod seal")
  • The Action Taken (e.g., "replaced pump motor bearings," "replaced seal kit in main press cylinder")
  • Parts Used and their cost
  • Labor Hours required

By consistently capturing this level of detail, you begin to build a rich historical database of your machine's health. You can start to answer critical questions: What is our most common failure? How long does a specific brand of hydraulic hose really last in our application? Is the higher cost of OEM block moulds justified by a longer lifespan compared to the aftermarket ones we tried last year? This historical analysis is the first step up from reactive maintenance and is the prerequisite for anything more advanced.

Introduction to Predictive Maintenance (PdM)

Predictive maintenance, sometimes called condition-based maintenance, takes this data-driven approach a step further. Instead of relying only on historical failure data, it uses real-time or periodic measurements of the machine's condition to detect the subtle signs of a developing failure. The goal is to catch the failure in its "P-F interval"—the time between the point where a potential failure is first detectable (P) and the point where it becomes a functional failure (F) (Moubray, 1997).

Several accessible PdM technologies can be applied to a brick machine:

  • Vibration Analysis: This is one of the most powerful PdM tools for rotating equipment. A trained technician uses a handheld data collector and accelerometer to take regular vibration readings from specific points on the machine, such as the motor and pump housings. The collected data is analyzed by software that can distinguish the unique vibration "signature" of a healthy machine from the signatures of developing problems like bearing wear, imbalance, misalignment, or looseness. It can often detect a failing bearing months before it would be audible to the human ear, allowing for it to be replaced during a planned shutdown.
  • Thermal Imaging (Infrared Thermography): An industrial infrared camera can instantly reveal the temperature of any component, visualized as a color image. A regular thermal scan of the machine can spot problems that manifest as excess heat. This includes overheating electric motor windings, clogged cooling fins, failing bearings (which generate heat through friction), and, critically, loose or corroded high-amperage electrical connections. A loose connection creates high resistance, which in turn generates intense heat and is a major fire hazard. A thermal scan can spot these "hot spots" long before they fail catastrophically.
  • Oil Analysis: Just as a blood test can reveal the health of a person, analyzing a sample of the machine's hydraulic oil can reveal the health of the hydraulic system. A laboratory can perform a series of tests on the oil sample to determine the viscosity, the presence of contaminants (like water, dirt, or silica from the environment), and, most importantly, the concentration of various wear metals (like iron, copper, and aluminum). An increasing trend of iron particles, for example, is a clear indicator that a steel component, like a pump gear or a cylinder wall, is wearing out. This gives a clear, data-based warning to plan for a component replacement.

Calculating the True ROI of Maintenance

One of the biggest hurdles to implementing a comprehensive maintenance program, particularly a more advanced predictive one, is justifying the cost. Management may see a new vibration analyzer or an oil analysis contract as an expense, not an investment. The key is to learn to speak the language of finance and demonstrate the return on investment (ROI).

The calculation is straightforward: ROI = (Gain from Investment – Cost of Investment) / Cost of Investment

Les Cost of Investment is easy to calculate: it's the cost of the training, tools, software, and labor for the proactive maintenance program.

Les Gain from Investment is the more complex but more powerful part of the equation. It is primarily the Cost of Failure Avoided. To calculate this, you must honestly and thoroughly estimate the full cost of a catastrophic, unscheduled failure of a critical component, like the main hydraulic pump. This cost includes:

  1. Cost of the replacement part (often with expedited shipping fees).
  2. Cost of labor for the emergency repair (often including overtime).
  3. Cost of lost production. This is the most significant number. If the machine is down for two days and it normally produces 50,000 bricks per day with a profit margin of $0.10 per brick, that's $10,000 in lost profit.
  4. Potential cost of cascading damage. A failing pump can send debris through the system, damaging expensive valves.
  5. Intangible costs, like damage to customer relationships from a delayed order.

When you sum these costs, the price of a single major failure can easily run into the tens of thousands of dollars. If your predictive maintenance program, which might cost a few thousand dollars a year, prevents just one such failure every few years, the ROI is enormous. Framing the discussion in these financial terms is the most effective way to secure the resources needed to properly care for your equipment and truly maximize the lifespan of a brick machine.

Foire aux questions (FAQ)

1. What is the average lifespan of a brick machine? The typical lifespan of a brick machine is generally between 8 and 15 years. However, this is not a fixed guarantee. A machine subjected to poor maintenance, harsh conditions, and untrained operators may fail in as little as 5-7 years. Conversely, a high-quality machine that benefits from rigorous maintenance, skilled operation, and strategic upgrades can readily exceed 20 years of productive service. The lifespan is less about the machine's age and more about its accumulated wear and the quality of its care.

2. Is a fully automatic machine more durable than a manual one? Not necessarily. Durability is more closely related to build quality, materials, and maintenance than the level of automation. A fully automatic concrete block machine often incorporates higher-quality components (like advanced PLCs and precision hydraulics) which can lead to greater long-term reliability if maintained correctly. However, their complexity also means there are more systems that can potentially fail. A simple, robustly built manual machine with fewer components might be more forgiving of neglect in the short term, but a well-maintained automatic machine will typically offer superior consistency and longevity over its entire life cycle.

3. How much does maintenance typically cost as a percentage of the machine's price? A common industry rule of thumb is to budget between 2% and 5% of the initial purchase price of the machine for maintenance costs annually. For a $150,000 machine, this would be $3,000 to $7,500 per year. In the early years, the cost will be lower and consist mainly of lubricants, filters, and labor for inspections. As the machine ages and major components like block moulds or hydraulic pumps require replacement, the annual cost will trend toward the higher end of that range. Investing consistently in this range is critical to avoiding much larger, unpredictable breakdown costs.

4. Can I use third-party block moulds with my machine? Yes, it is often possible to use third-party or aftermarket block moulds. However, this requires careful consideration. You must ensure the aftermarket mold is dimensionally identical to the OEM version and is designed to mount correctly and safely in your machine. The quality of the steel and the heat treatment used by the aftermarket supplier are paramount. A low-quality mold may wear out quickly or even fail catastrophically, potentially damaging the tamper head or press. It is best to use reputable aftermarket suppliers who can provide material specifications and references.

5. What are the first signs that a brick machine needs a major overhaul? The early signs are often subtle. They include a consistent decline in brick quality (e.g., poor dimensional accuracy, chipping), a noticeable increase in the machine's cycle time, or the need to constantly adjust pressure settings to get a good product. Other indicators are an increase in the frequency of minor breakdowns, a rise in hydraulic fluid temperature beyond the normal range, and new, persistent noises or vibrations from the machine's core systems. These symptoms suggest that multiple components are worn and that a planned major overhaul is needed to restore performance and prevent a complete breakdown.

6. How does the quality of raw materials affect the lifespan of a brick machine? The quality of raw materials has a profound effect. Using aggregates with sharp, angular particles or a high silica content significantly increases the rate of abrasive wear on all surfaces they contact, including mixer liners, conveyor belts, and especially the expensive block moulds. Inconsistent moisture content in the mix forces the hydraulic system to work harder and less predictably. Contaminants like clay or organic matter can affect brick quality and build up on machine components. Using clean, properly graded, and consistent raw materials is a foundational requirement for reducing mechanical stress and extending machine life.

Conclusion

The question of a brick machine's lifespan is, in its essence, a question of stewardship. It is a narrative written not in the factory where the machine was built, but in the daily, weekly, and yearly actions of the people who own and operate it. We have seen that longevity is not a passive property but an active achievement, a direct result of a holistic and disciplined approach. It begins with a foundational respect for the machine, rooted in an understanding of its mechanical and physical principles. From this understanding grows a culture of rigorous, proactive maintenance—a rhythm of care that anticipates needs rather than reacting to crises.

This culture is embodied by the skilled operator, who acts as the machine's first guardian, and is supported by a controlled environment that shields the asset from the unseen enemies of moisture, dust, and electrical instability. It is sustained by a strategic approach to components, treating spare parts not as a cost but as insurance against downtime, and by the wisdom to embrace modernization, allowing the machine to evolve and adapt. Finally, this entire effort is refined and directed by the power of data, transforming maintenance from a practice of guesswork into a science of prediction. Ultimately, the lifespan of a brick machine is a direct reflection of the owner's commitment. By embracing these principles, one does more than simply make a machine last longer; one builds a more resilient, reliable, and profitable enterprise for the long term.

Références

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Swanson, L. (2001). Linking maintenance strategies to performance. International Journal of Production Economics, 70(3), 237–244. (00)00067-0

Quanzhou City Sanlian Machinery Manufacture. (2025, September 16). A practical 7-step guide on how to make a compressed earth brick machine in 2025. Sanlianblockmachine.com. https://www.sanlianblockmachine.com/pt/a-practical-7-step-guide-on-how-to-make-a-compressed-earth-brick-machine-in-2025/

Qunfeng Group. (2025, March 19). Brick production machine ensures efficiency and durability. Qunfenggroup.com. https://www.qunfenggroup.com/brick-production-machine

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Hongfa Construction. (2018, October 16). Outstanding concrete brick production line. Hfmachines.com.