This document provides information about Fahad Al-Harbi's summer training at Elmaimani Red Brick and Clay Products Factories in Madinah, Saudi Arabia. It describes the brick manufacturing process, including material preparation, extrusion, drying, and packaging. It also lists Fahad's responsibilities in quality control, maintenance, and operating machines like the wet pan mill and vacuum chamber extruder. The document details procedures for quality testing, replacing die molds, and troubleshooting issues with a pump.

1. Yanbu Industrial College
Department of Mechanical
Engineering Technology
MET
D
E
P A R T M E N
T
MECHANICAL
ENGINEERING
T
ECHNOLOGY

2. SUMMER TRAINING:MET 400
Prepared By Supervisor By
Fahad AL- Harbi Dr. M. Shukri
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3. 1. Introduction.
2. Manufacturing process of bricks.
3. Practical Training.
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4. Elmaimani Red Brick
and
Clay products factories
• It was found in 1980 in Madina
Munawara.
• Considered as one of the biggest brick
manufacturing companies in the Kingdom
of Saudi Arabia.
• It produces nearly 2000 tons per day of red
clay brick in different types ,sizes and colors
• It is considered as the first company who
has introduced the Load Bearing
Construction System in the construction
field.
Some projects
from
Elmaimani factories
• Old Madina Mosque like Quba,
Qiblatain and Miqath .
• Group of Private Villas for Aramco
Staff in Industrial Yanbu City.
• Saraya Compound – Bahrain.
• Dorrat Al Aroos Resort – Jeddah.
• Residential District - Yanbu
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6. MATERIAL
PREPARATION
WET
PREPARATION
EXTRUSION
SETTING
MACHINE
TUNNEL
DRYER
TUNNEL KILN
UNLOADING
MACHINE
PACKING
Sand Box
Feeder
Wet Pan
Mill
Coarse
Roller
Mill Fine
Roller
Mill
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8. Locations / Customer
Grouping And Setting
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The job I did is I worked as an operator for some of
their machines. The main section in the company I
worked in are:-
• Quality Control (Q.C) Department.
• Maintenance Department – Machinery & Shops.
• Maintenance Department – Mechanical Field.
• Technical Department – Inspection Group.

10. • Performance of wet pan mill scrapers and its
guide. condition of clay spreaders.
• Always refer to Lab. Sieve Test and
Moisture content results one hour after
operation had started and make
necessary adjustment if necessary.
• Before the start of each shifts operation
the operator is required to check the
following :-
• Condition of box feeder's slat conveyor
speed setting and sand silo setting.
While operating routinely and frequently
check the following-:
•Sizes, type and quantity of materials being fed by
loading shovel operators.
•Box feeder paddle shafts.
•Slat conveyor links and slat.
•Always use metal detector. Material spillages
piling-up of the tail end of the conveyors and
metal structures holding the conveyors must be
regularly removed.
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Paddle bladesPaddle shaft
ScrapersWet Pan Mill

11. •Possible leakage in the vacuum
chamber will occur if any of the
following conditions exist.
1.Uncleaned tapered hubs or if the hubs
have a lot of dry and hard clay build up.
2.Insufficient feeding of material.
3.Leakages in pipes, barrels and doors.
•There are occasions that vacuum is low
or insufficient in this regard the
following measures have to be taken.
1.Check the temperature. This should
not go higher than 80°C.
2.Check vacuum filters.
3.Check the pump.
4.Check the suction pipe for leakage.
5.Check the suction pipe for leakage.
•Clearance or condition of wet pan mill
roller scrapers and conveyor scrapers.
•Condition of motor drive belts.
•Conduct determination of roller mill
clearance regularly and properly (Half
Hour before each shift ends). Hardened
material sticking to the surface of the
rollers must be removed before feeding the
copper wire.
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Vacuum Chamber

12. •PROCEDURE IN CHANGING THE DIE MOULD
•Empty the slat conveyor and the conveyor after the die
mould.
•Loosen the bolts firmly holding the die mould. wait for a
few minutes for the pressure to drop.
•Switch-On the clutch for the extruder at manual to push
the die mould and the clay in the pressure head.
•Remove the clay that is in the pressure head up to the
point where the vacated space is good enough for the die
mould to be fitted.
•Fit-in the die mould, check for its levelness, and put back
all the bolts.
•Before re-starting up ensure that the bolts are firmly and
tightly fix.
•Refill the die mould with material by manually operating
the extruder, until the die mould is complete filled.
•Level the green conveyor, cutting table, black belts and
other conveying system.
•Start the operation in automatic mode.
•At running time, check the cutting length.
Perpendicularity, Pressure and Vacuum.
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13. DEPARTMENTLABORATORY Q.C
SIEVE ANALYSIS TEST
DRY CLAY + SAND + WATER MIXING WET CLAY
PRODUCED
Measuring test ( sand test)
1.500 grams wet clay took in water in few minutes. After that
clay washing thru 200 MESH (+0.075 mm).
Now all clay going out from above mesh. Sand get from
mesh.
1.Above sand 45 minutes put in oven for dry. Dry after that
sample put in various size of mesh no. 09 , 16 ,18 ,20 ,100 ,200
for analysis.
2.Total grams ÷ dry weight ×100 = Equivalent % 38 – 40 % is
good for produced bricks.
3.M.C. Test to get % water, 100 Grams wet material put in
oxen 45 minutes after take and weight.
4.M.C Test
=
13
For example :
M.C Test =
= = 17.64 M.C %

14. 14
Coro vane Pump
• Problem: There is a noise in the unloading Diesel
pump- and take long time to full Diesel tank which has
capacity 36000 liter/min.
Sol.
So, this time to fully the diesel tank.
How to make evaluation of the new
pump?
Bring 4 drums of empty oil of lubrication and
raining the pump to give liquid to the 4 drums
and calculate the time need to full 4 drums by
stop watch.

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t = 60 sec = 1 min
We check the pipe line, then we find the problem in the
float valve it plugged.

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And send the pump to maintenance department to replace it and solve the
noise, after one hour we find the problem noise in the vanes.
final steps change the vane according to the guidance manual.

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Thank you
If you have any question?