Kiln Car Stacking and Hack Pattern Verification

Inspection template for verifying brick stacking pattern, course height, spacing, and load stability on kiln cars to support even firing, airflow, and safe material handling.

Inspection Details

• Kiln car ID recorded
  Record the kiln car identifier, line, or position being inspected.
• Product / brick type recorded
  Record the brick product, size, or setting pattern specification being used.
• Inspection date and time captured
  Document when the stacking verification was completed.
• Inspector identified
  Record the name or employee ID of the setting machine operator or inspector.
• Reference setting pattern or SOP available
  Verify the current hack pattern drawing, work instruction, or SOP is available at point of use.

Stacking Pattern and Course Layout

• Brick stacked in the correct hack pattern
  Verify the load matches the approved hack pattern for the product and kiln car layout.
• Course height matches specification
  Measure the course height against the approved setting specification.
• Horizontal spacing between bricks is consistent
  Measure representative spacing between bricks to confirm airflow channels are maintained and spacing is uniform.
• Stack alignment remains centered on kiln car
  Verify the load is centered and does not overhang the kiln car deck or create an imbalance.

Load Stability and Safe Stacking

• Stack is stable with no visible lean, shift, or collapse risk
  Check for leaning courses, displaced bricks, voids, or other instability that could lead to collapse during movement or firing.
• Maximum stack height within site limit
  Measure the overall stack height and confirm it does not exceed the site-approved maximum for kiln car loading.
• Backset applied above upper stacking threshold
  Verify the required backset or step-back is present in upper courses where the stack rises above the site threshold.
• No damaged or broken bricks compromising the stack
  Check for cracked, chipped, or broken bricks that reduce load stability or disrupt the firing pattern.

Airflow and Firing Path Verification

• Airflow channels remain open through the load
  Verify the stacking pattern leaves intended airflow paths open for even firing and heat circulation.
• No blocked burner, flue, or circulation openings
  Confirm the load does not obstruct burner paths, flues, or other kiln car openings required for firing.
• Pattern is uniform across the full kiln car load
  Check that the hack pattern is consistent from front to back and side to side, with no irregular gaps or dense sections.

Corrective Actions and Sign-Off

• Deficiencies documented with location and description
  Record any non-conformance, including the exact location on the kiln car and the nature of the issue.
• Corrective action completed before release
  Confirm any identified deficiencies were corrected before the kiln car was released for firing or movement.
• Re-inspection completed after correction
  Verify the load was rechecked after any adjustment or rework.
• Inspector signature
  Inspector signs to confirm the kiln car stacking verification is complete and accurate.