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Run: Kiln Car Stacking and Hack Pattern Verification

Verify kiln car brick stacking, hack pattern, course height, spacing, and load stability before firing. This template helps catch airflow restrictions and un...

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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.

Yes No N/A

Stacking Pattern and Course Layout

Brick stacked in the correct hack pattern critical (required)

Verify the load matches the approved hack pattern for the product and kiln car layout.

Yes No N/A

Photo evidence (optional)

Course height matches specification critical (required)

Measure the course height against the approved setting specification.

Horizontal spacing between bricks is consistent critical (required)

Measure representative spacing between bricks to confirm airflow channels are maintained and spacing is uniform.

Stack alignment remains centered on kiln car critical (required)

Verify the load is centered and does not overhang the kiln car deck or create an imbalance.

Yes No N/A

Photo evidence (optional)

Load Stability and Safe Stacking

Stack is stable with no visible lean, shift, or collapse risk critical (required)

Check for leaning courses, displaced bricks, voids, or other instability that could lead to collapse during movement or firing.

Yes No N/A

Photo evidence (optional)

Maximum stack height within site limit critical (required)

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 critical (required)

Verify the required backset or step-back is present in upper courses where the stack rises above the site threshold.

Yes No N/A

Photo evidence (optional)

No damaged or broken bricks compromising the stack

Check for cracked, chipped, or broken bricks that reduce load stability or disrupt the firing pattern.

Yes No N/A

Photo evidence (optional)

Airflow and Firing Path Verification

Airflow channels remain open through the load critical (required)

Verify the stacking pattern leaves intended airflow paths open for even firing and heat circulation.

Yes No N/A

Photo evidence (optional)

No blocked burner, flue, or circulation openings critical (required)

Confirm the load does not obstruct burner paths, flues, or other kiln car openings required for firing.

Yes No N/A

Photo evidence (optional)

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.

Yes No N/A

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 critical (required)

Confirm any identified deficiencies were corrected before the kiln car was released for firing or movement.

Yes No N/A

Re-inspection completed after correction critical (required)

Verify the load was rechecked after any adjustment or rework.

Yes No N/A

Inspector signature

Inspector signs to confirm the kiln car stacking verification is complete and accurate.

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