For nearly 70 years, Triangle Brick has been a one-stop shop, manufacturing high-quality clay brick for sale in the United States. Our decades-long commitment to innovation and optimization has pioneered new industry standards around sustainability, safety and inventory consistency.
We’re not just showing you how brick is made — we’re proving #BrickByTBC is better from the very beginning.
Our excavators extract clay and shale from the Triassic Basin’s dense mineral deposits before dump trucks haul the raw earth to a powerful crusher. Here, the massive boulders are broken down into softball-sized pieces ready for production.
We transport these newly sized pieces to our expansive raw material storage, joining the existing stockpile of blended clay and shale awaiting further processing. A large impact grinder pulverizes the mixed material into a powder-like consistency, which is then stored securely in concrete bunkers.
Raw material from the bunkers is mixed with water and de-aired in a pug mill. It is then pushed through a die by an extruder to form an 18-foot clay ribbon. During the facing process, special coloring and textures are applied to the ribbon’s outer surface to create Triangle Brick’s distinctive finishes. This ribbon is trimmed and cut into 110-inch sections before moving to the setting machine.
The setting machine uses industrial computers to cut the clay column into green (unfired) brick and add any extra texture. Robots then blend, layer and set each piece onto kiln cars in precise patterns. TBC pioneered this first-of-its-kind, advanced automation process to seamlessly adjust sizing, spacing and settings for maximum efficiency and consistency in our brick for sale.
Our recovery rate of more than two million bricks per week (at capacity) is greater than 99 percent. This cuts waste seen in traditional brick manufacturing while saving our clients time and money.
Our plants process up to 26 TONS of raw material every hour – adding to a material stockpile capable of producing 4 million bricks at any given time.
Every 90 minutes, a kiln car carries green brick into a holding room before entering the dryer-kiln system. There, heat from the now-cooling, previously fired brick helps remove moisture from the incoming green brick. As they progress through preheating, burning and flashing at roughly 1,900°F, raw gas reacts with iron in the brick to create our signature rich brown, gray and black tones.
After firing, the bricks move into a cooling zone that locks in their color and ensures lasting quality. This process is carefully managed within a fully computer-controlled, state-of-the-art kiln – one of the largest tunnel kiln systems in the United States. Thanks to our advanced insulation and heat control technology, we manufacture brick at an unmatched scale with consistently superior quality.
The bricks exiting the kiln are programmed to move to the storage tracks to await blending and bundling into the final package, Triangle Brick’s revolutionary Half-Pack™. Thanks to our automatic unloaders and industrial robots, our brick color ranges are blended during packaging, a process that saves our masons and bricklayers valuable time during installation.
For our national distribution, two half-packs are strapped together to create the traditional shipping cube. The cubes are automatically moved to a roller conveyor for forklift pickup. Next stop? The Triangle Brick shipment-ready inventory yard or a delivery vehicle.
Cubes are sorted, moved to an inventory line and made available to our national brick distributors through our 24/7 customer portal, TBC Central. Delivery drivers use our innovative online kiosk to dispatch bricks for shipment, ensuring clients get real-time delivery updates, whether it’s shipped by road or by rail!
Delivery Services
Throughout our entire manufacturing process, assembling our sample boards is actually the first time a Triangle Brick is handled by human hands. Every other facet of production is fully-automated to offer a seamless production experience and shipment-ready brick at an unmatched scale. Our sample boards are then taken on the road by our national sales team or available to explore in our NC Design Center!
Visit the Design Center
